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<125-µA Standby, High-Efficiency Power Supply
Reference Design for Neutral-less Wireless Lighting
Controls
Description
Features
Lighting control devices such as wired or wireless
switches and dimmers may be used in retrofit
environments or in new installations. New installations
may have separate line, neutral, and earth wires
where the lighting control unit can be powered by
connecting it between the line and neutral, whereas in
most of the retrofit installations only line and earth
wires may be available. In such cases, the lighting
control unit has to be powered by connecting it
between line and earth terminals while ensuring that
the current flowing to earth is limited to 0.5 mA. This
necessitates the use of a very low standby
consumption, high efficiency power supply.
•
This TI Design is a wireless lighting control unit using
a low quiescent current offline converter that enables
excellent efficiency at low power levels, a low-noise,
high-PSRR, low quiescent current, good line and load
transient response LDO, and a very low standby and
low active current specs wireless microcontroller.
•
•
•
•
•
<125-µA Quiescent Current Including Wireless
MCU and 69% Efficiency at 35-mW Load
Offline Converter With Integrated 700-V Power
MOSFET
High-Side Current Limit Circuit With Inherent Inrush
Current Limiting, Output Overload, and ShortCircuit Protections
Low Noise, High PSRR, Low Quiescent Current,
Good Load Transient Response LDO for Wireless
Control
Tested and Characterized With SimpleLink
Bluetooth® Low Energy Wireless MCU Having 1µA Standby, Low Rx, Tx, Core and Sensor
Controller Currents Enabling Easy Implementation
Of Lighting Controls
Enables Neutral-less Lighting Control Applications
With Earth as Return That Complies With UL773A
Applications
Resources
•
TIDA-01097
UCC28881
LP5912
CC2650MODA
TPD6E004
Design Folder
Product Folder
Product Folder
Product Folder
Product Folder
•
•
•
Neutral-less or No Neutral Wireless Lighting
Control Switches, Dimmers
Photo Control Units
Occupancy and Vacancy Sensors
Motion Sensors
ASK Our E2E Experts
TIDA-01097
RF board
Power supply board
EMI filter
CC2650MODA
Current
limiter
L
110-V AC
input
E/N
5
+
Rectifier
UCC28881
(Integrated 700-V
MOSFET)
±
LP5912 LDO
+
3.3V
PG/
RST
GND
TPD6E004
ESD
JTAG
connector
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<125-µA Standby, High-Efficiency Power Supply Reference Design for
Neutral-less Wireless Lighting Controls
Copyright © 2016, Texas Instruments Incorporated
1
System Overview
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An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other
important disclaimers and information.
1
System Overview
1.1
System Description
Lighting control units play an important role in increasing the energy efficiency of commercial and
residential buildings. Lighting control may be wired or wireless, with wireless control adoption increasing
due to wiring elimination and increased ease of installation. Wireless control consists of simple wireless
switches, keypads, dimmers, and sensors. Wireless controls commonly need a compact power supply that
may be able to deliver power in the range of sub 100 mW. One of the primary requirements for wireless
control power supplies is that they need to have ultra-low quiescent current as they are always "on". The
second important requirement is that they need to be compact with high integration.Figure 1 and Figure 2
show typical implementation of Neutral less Lighting control (switches, dimmers) application
L
Encrypted wireless connection between
lighting control and LED driver
TIDA-01097
N
AC
input
L
TIDA-01097
Power supply
board
110-V AC
input
TIDA-01097
RF board
(Wireless
lighting control)
LED driver with
wireless receiver
module
LED
lamp
E
Input from user to turn
ON/OFF and perform
dimming operations
User input control
Copyright © 2016, Texas Instruments Incorporated
Figure 1. Neutral-less Wireless Lighting Control Application
2
<125-µA Standby, High-Efficiency Power Supply Reference Design for
Neutral-less Wireless Lighting Controls
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L
110-V AC
input
Neutral-less TRIAC dimmer
TIDA-01097
N
VDD
L
TIDA-01097
Power supply
board
110-V AC
input
TIDA-01097
RF board
(Wireless
lighting control)
LED+
GND
E
Input from user to turn
ON/OFF and perform
dimming operations
LED driver
CNTL
LED
lamp
LED±
TRIAC driver
Wired connection between lighting control
and LED driver
User input control
Copyright © 2016, Texas Instruments Incorporated
Figure 2. Neutral-less TRIAC Dimming Application
Installing lighting controls in retrofit applications is more challenging because the older installations may or
may not have the neutral wire or the grounded circuit conductor. In such cases, the lighting control unit
has to be powered by connecting the unit between the hot wire (line terminal) and the earth wire or ground
terminal. The UL773A does allow it with certain restrictions and one of the important requirements is that
the current flowing through the ground should be limited to 0.5 mA. This is to ensure that the ground
current does not exceed the trip limit of the earth leakage circuit breaker, which may be there in the circuit.
In order to meet this requirement and at the same time generate the maximum possible power for
powering the lighting control circuit components, the power supply has to be efficient and should have a
very low quiescent current. The TI Design TIDA-01097 is designed for such an application leveraging the
low quiescent current of the offline converter and the low quiescent current LDO. The reference design is
also tested for powering the low energy wireless MCU and characterization data is provided for reference.
While this power supply is meant for lighting control systems in a retrofit environment without neutral, it
can also be used in newer buildings where neutral wire is readily available. Although the TIDA-01097 is
designed and tested for a 3.3-V, 10-mA output, one can redesign the system easily to provide different
voltage and higher power.
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System Overview
1.2
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Key System Specifications
Table 1. Key System Specifications
PARAMETER
SYMBOL
TEST CONDITIONS
MIN
TYP
MAX
UNIT
INPUT CHARACTERISTICS
Input AC voltage
VIN_AC
93.5
110
126.5
V
Frequency
FAC
—
60
—
Hz
Minimum voltage to
start-up
VHVIN(min)
—
30
—
V
Input AC current
IIN_AC
100
500
800
µA
V
OUTPUT CHARACTERISTICS
Output voltage
Output current
VLDO_IN
Voltage before LDO at VIN_AC = 110 V
3.55
3.60 (1)
3.58
VLDO_OUT
Voltage after LDO
3.230
3.294
3.360
V
IOUT
VIN_AC = 110 V
0.005
6.75 (2)
10.74
mA
Output voltage ripple
Ripple before LDO at VIN_AC = 110 V
72
—
240
mV
VIN_AC = 110 V , IIN_AC = 740 µA
—
33.2
—
mW
Efficiency
VIN_DC = 155.5 V, IIN_DC = 374 μA
—
68.9 (3)
—
%
Protections
Overload, output short-circuit, and
over-temperature protections (4)
Output power
(1)
(2)
(3)
(4)
1.3
PLDO_OUT
Output voltage before LDO is specified at IIN_AC = 500 μA.
Output current is specified at IIN_AC = 500 μA.
The efficiency is specified for the flyback power stage only excluding the bridge rectifier, the current limiter circuit at the input,
and the LDO at the output. The DC input voltage applied is 155.5 V.
The protections specified are features of the UCC28881 device used in the TI Design.
Block Diagram
TIDA-01097
RF board
Power supply board
EMI filter
CC2650MODA
Current
limiter
L
110-V AC
input
E/N
5
+
Rectifier
UCC28881
(Integrated 700-V
MOSFET)
LP5912 LDO
±
+
3.3V
PG/
RST
GND
TPD6E004
ESD
JTAG
connector
Copyright © 2016, Texas Instruments Incorporated
Figure 3. TIDA-01097 Block Diagram
4
<125-µA Standby, High-Efficiency Power Supply Reference Design for
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1.4
1.4.1
Highlighted Products
UCC28881 700-V, 225-mA Low Quiescent Current Offline Converter
The UCC28881 integrates the controller and a 14-Ω, 700-V power MOSFET into one monolithic device.
The device also integrates a high-voltage current source, enabling start-up and operation directly from the
rectified mains voltage.
The low quiescent current of the device enables excellent efficiency. With the UCC28881, the most
topologies common converter topologies such as buck, buck-boost, and flyback can be built using a
minimum number of external components. The UCC28881 incorporates a soft-start feature for the circuit
controlled start-up of the power stage, which minimizes the stress on the power-stage components.
The key features that make this device unique are:
• Integrated 14-Ω, 700-V MOSFET
• Integrated high-voltage current source for internal device bias power
• Integrated current sense
• Internal soft start
• Self-biased switcher, thus no aux winding required on inductor or transformer to bias the controller
• Supports buck, buck-boost and flyback topologies
• <100-μA device quiescent current
• Robust current protection during load short circuit
• Protection features such as current limiter, overload, and output short circuit, and undervoltage lockout
HVIN
5
High Voltage
Current Source
8
Thermal
Shutdown
VDD
4
Gate
LDO
UVLO
DRAIN
S
Q
R
Q
Current
Limit
Control and
Reference
VREF_TH = 1 V
+
FB
3
PWM Controller
and Output Short
Circuit Protection
Leading Edge
Blanking Time
LEB
1, 2
GND
Copyright © 2016, Texas Instruments Incorporated
Figure 4. Functional Block Diagram of UCC28881
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System Overview
1.4.2
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LP5912 500-mA Low-Noise, Low-IQ LDO
The LP5912 is a low-noise LDO that can supply up to 500 mA of output current. Designed to meet the
requirements of RF and analog circuits, the LP5912 device provides low noise, high PSRR, low quiescent
current, and low line and load transient response. The LP5912 offers class-leading noise performance
without a noise bypass capacitor and with the ability for remote output capacitance placement. The device
is designed to work with a 1-μF input and a 1-μF output ceramic capacitor (no separate noise bypass
capacitor required). This device is available with fixed output voltages from 0.8 to 5.5 V in 25-mV steps.
Contact Texas Instruments Sales for specific voltage option needs.
The key features that make this device unique are:
• Input voltage range: 1.6 to 6.5 V
• Output voltage range: 0.8 to 5.5 V
• Output current: up to 500 mA
• Low output-voltage noise: 12 μVRMS typical
• PSRR at 1 kHz: 75 dB typical
• Output voltage tolerance (VOUT ≥ 3.3 V): ±2%
• Low IQ (enabled, no load): 30 μA typical
• LDO (VOUT ≥ 3.3 V): 95 mV typical at a 500-mA load
• Stable with 1-μF ceramic input and output capacitors
• Thermal-overload and short-circuit protection
• Reverse current protection
• No noise bypass capacitor required
• Output automatic discharge for fast turnoff
• Power-good output with 140-μs typical delay
• Internal soft-start to limit the inrush current
• –40°C to 125°C operating junction temperature range
Current
Limit
IN
OUT
RAD
100
45 k
VIN
EA
Output
Discharge
+
±
VBG
PG
EN
Control
EN
140-µs
DELAY
3M
GND
Copyright © 2016, Texas Instruments Incorporated
Figure 5. LP5912 Functional Block Diagram
6
<125-µA Standby, High-Efficiency Power Supply Reference Design for
Neutral-less Wireless Lighting Controls
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1.4.3
CC2650MODA SimpleLink™ Bluetooth® Low Energy Wireless MCU Module
The SimpleLink CC2650MODA device is a wireless microcontroller (MCU) module that targets Bluetooth
low energy (BLE) applications. The CC2650MODA device can also run ZigBee® and 6LoWPAN and
ZigBee RF4CE™ remote control applications.
The module is based on the SimpleLink CC2650 wireless MCU, a member of the CC26xx family of costeffective, ultra-low-power, 2.4-GHz RF devices. Very-low active RF and MCU current and low-power mode
current consumption provide excellent battery lifetime and allow for operation on small coin-cell batteries
and in energy-harvesting applications.
The CC2650MODA module contains a 32-bit ARM Cortex-M3 processor that runs at 48 MHz as the main
processor and a rich peripheral feature set that includes a unique ultra-low-power sensor controller. This
sensor controller is good for interfacing with external sensors or for collecting analog and digital data
autonomously while the rest of the system is in sleep mode. Thus, the CC2650MODA device is good for
applications within a wide range of products including industrial, consumer electronics, and medical
devices.
The CC2650MODA module is pre-certified for operation under the regulations of the FCC, IC, ETSI, and
ARIB. These certifications save significant cost and effort for customers when integrating the module into
their products.
The BLE controller and the IEEE 802.15.4 MAC are embedded in the ROM and are partly running on a
separate ARM® Cortex®-M0 processor. This architecture improves overall system performance and
power consumption and makes more flash memory available.
The key features that make this device unique are:
• Operation from 1.8 to 3.8 V
• Active-Mode RX: 6.2 mA
• Active-Mode TX at 0 dBm: 6.8 mA
• Active-Mode TX at 5 dBm: 9.4 mA
• Active-Mode MCU: 61 µA/MHz
• Active-Mode MCU: 48.5 CoreMark/mA
• Active-Mode sensor controller: 0.4 mA + 8.2 µA/MHz
• Standby: 1 µA (RTC running and RAM/CPU retention)
• Shutdown: 100 nA (wake-up on external events)
• 2.4-GHz RF transceiver compatible with BLE 4.2 Specification and IEEE 802.15.4 PHY and MAC
• Excellent receiver sensitivity (–97 dBm for BLE and –100 dBm for 802.15.4), selectivity, and blocking
performance
• Programmable output power up to 5 dBm
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System Overview
1.4.3.1
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Sensor Controller
The sensor controller contains circuitry that can be selectively enabled in standby mode. The peripherals
in this domain may be controlled by the sensor controller engine, which is a proprietary power-optimized
CPU. This CPU can read and monitor sensors or perform other tasks autonomously, thereby significantly
reducing power consumption and offloading the main CM3 CPU.
The sensor controller is set up using a PC-based configuration tool called Sensor Controller Studio™ and
typical use cases may be (but are not limited to):
• Analog sensors using integrated ADC
• Digital sensors using GPIOs and bit-banged I2C or SPI
• UART communication for sensor reading or debugging
• Capacitive sensing
• Waveform generation
• Pulse counting
• Keyboard scan
• Quadrature decoder for polling rotation sensors
• Oscillator calibration
The peripherals in the sensor controller include the following:
• The low-power clocked comparator can be used to wake the device from any state in which the
comparator is active. A configurable internal reference can be used with the comparator. The output of
the comparator can also be used to trigger an interrupt or the ADC.
• Capacitive sensing functionality is implemented through the use of a constant current source, a timeto-digital converter, and a comparator. The continuous time comparator in this block can also be used
as a higher-accuracy alternative to the low-power clocked comparator. The sensor controller will take
care of baseline tracking, hysteresis, filtering and other related functions.
• The ADC is a 12-bit, 200-ksamples/s ADC with eight inputs and a built-in voltage reference. The ADC
can be triggered by many different sources, including timers, I/O pins, software, the analog
comparator, and the RTC.
• The sensor controller also includes a SPI/I2C digital interface.
• The analog modules can be connected to up to eight different GPIOs.
8
<125-µA Standby, High-Efficiency Power Supply Reference Design for
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SimpleLinkTM CC2650MOD Wireless MCU Module
32.768-kHz
Crystal
Oscillator
24-MHz Crystal
Oscillator
Antenna
RF Balun
GND
1
25 GND
NC
2
24 NC
GND
3
23 VDD
ADC
DIO 0
4
22 VDD
ADC
DIO 1
5
cJTAG
RF core
ROM
Main CPU:
128-KB
Flash
ARM®
Cortex®-M3
Digital PLL
DSP Modem
8-KB
Cache
20-KB
SRAM
15 GPIOs
TRNG
AES
Temp. / Batt. Monitor
32 ch. µDMA
RTC
12-bit ADC, 200 ks/s
18 DIO 11
(Exposed GND Pads)
17 DIO 10
JTAG_TMS 9
10
11
12
2× Analog Comparators
13
14
15
16
DIO 9
Watchdog Timer
19 DIO 12
DIO 8
I2S
8
G4
nRESET
2× SSI (SPI, µWire, TI)
DIO 4
G3
20 DIO 13
DIO 7
UART
Sensor Controller Engine
7
DIO 6/JTAG_TDI
4× 32-bit Timers
Sensor Controller
DIO 3
DIO 5/JTAG_TDO
I2C
ROM
6
G2
JTAG_TCK
General Peripherals / Modules
ARM®
Cortex®-M0
4-KB
SRAM
DIO 2
21 DIO 14
G1
SPI / I2C Digital Sensor IF
Constant Current Source
Time-to-Digital Converter
DC-DC converter
2-KB SRAM
Copyright © 2016, Texas Instruments Incorporated
Figure 6. CC2650MODA Block Diagram
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Figure 7. CC2650MODA Pin Diagram
<125-µA Standby, High-Efficiency Power Supply Reference Design for
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System Overview
1.4.4
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TPD6E004, Low-Capacitance, 6-Channel ±15-kV ESD Protection Array for High-Speed Data
Interfaces
The TPD6E004 device is a low-capacitance, ±15-kV ESD-protection diode array designed to protect
sensitive electronics attached to communication lines. Each channel consists of a pair of diodes that
steers ESD current pulses to VCC or GND. The TPD6E004 protects against ESD pulses up to ±15-kV
human body model (HBM), ±8-kV contact ESD, and ±12-kV air-gap ESD as specified in IEC 61000-4-2.
This device has a typical 1.6-pF capacitance per channel, making it ideal for use in high-speed data I/O
interfaces.
The TPD6E004 device is available in the RSE package and is specified for –40°C to 85°C operation. The
TPD6E004 device is a six-channel ESD structure designed for USB, Ethernet, FireWire, and JTAG
applications.
VCC
IO1
IO2
IO3
IO4
IO5
IO6
GND
Copyright © 2016, Texas Instruments Incorporated
Figure 8. Functional Block Diagram of TPD6E004
10
<125-µA Standby, High-Efficiency Power Supply Reference Design for
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System Design Theory
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2
System Design Theory
This reference design is a power supply for producing a 3.3-V output. For neutral-less lighting control, as
the current flowing to the earth terminal has to be limited to 0.5 mA only, the power supply has a linear
current limiter circuit implemented using discrete components. Following the current limiter is a nonisolated flyback power supply with output voltage feedback for the regulation. The output voltage from
flyback is used for powering a wireless MCU module through the LP5912 LDO. The LDO helps in
regulation and as well as reduction of flyback output ripple voltage.
2.1
Input Current Limiter Design
Figure 9 shows a simple current limiter circuit implementation. It uses a MOSFET as a series pass
element to control the current.
Vin
Vin
Sensing Resistor (R4)
N-Channel MOSFET (Q1)
3
1
4
C
2
3
Bias Resistor (R1)
Load Capacitor (C)
NPN Transistor (Q3)
Copyright © 2016, Texas Instruments Incorporated
Figure 9. Current Limit Circuit Implementation
The current sense resistor along with the NPN transistor (Q3) senses the current through the circuit and
regulates the MOSFET gate voltage to control the current. The current limit value for this circuit is set by
sense resistor (R4) and base to emitter junction voltage (VBE) of transistor Q3 and is calculated by
Equation 1.
Current limit = (
Current sense resistor (R 4 )
Base to emitter junction voltage V BE
)
(1)
Although this circuit can work, it has certain limitations. The current-sense resistor, R4, in Figure 9 does
not sense the bias current. Hence, when the input terminal voltage increases, it causes increase in bias
current which in turn causes the current limit to increase. This change in current limit with respect to the
change in line voltage conditions will not be desirable. The other limitation is the change in current limit
due to the negative temperature coefficient of the NPN transistor(Q3). The negative temperature coefficient
of the base-to-emitter junction causes the current value to vary widely with temperature.
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System Design Theory
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Figure 10 shows the modified current limiter circuit that mitigates these two limitations.
FCD4N60TM
Q1
3
1
4
Vin
R2
100k
100k
MMBT3906-7-F
Q2 3
2
R4
5.11k
1
R1
1
R3
17.8k
3
Q3
D2
2
MMBT2222ALT1G
1SMB5919BT3G
5.6V
Copyright © 2016, Texas Instruments Incorporated
Figure 10. Modified Current Limiter Circuit
Resistor R3 and PNP transistor Q2 form a constant-current source to the collector of Q3. The circuit diverts
any excess bias current through the collector of Q2 to sense resistor R4. Thus, as the terminal voltage
increases, the bias current remains relatively constant, and the current regulation appears much flatter.
The negative temperature coefficient of the base-to-emitter junction of transistor Q3 causes another
problem with this kind of circuit. The temperature coefficient is approximately −1.6 mV/°C, which causes
the current value to vary widely with temperature. One way to approach this problem is to add a 5.6- to
6.2-V Zener diode, D2, in series with the emitter of Q3, which increases the sense voltage (Figure 10). A
5.6-V diode has a positive temperature coefficient, which counteracts the negative temperature coefficient
of the transistor. Furthermore, the total sense voltage is much larger, so 100 mV or so of a voltage change
with temperature does not seriously affect the regulated current.
2.2
Flyback Circuit Component Design
This section details the design process and component selection a designer must follow to complete a
flyback converter using the UCC28881.
2.2.1
Design Goal Parameters
Table 2 states the design goal parameters for this design. These parameters are used in further
calculations to select components.
Table 2. Design Goal Parameters
PARAMETER
DESCRIPTION
MIN
TYP
MAX
UNIT
INPUT CHARACTERISTICS
VIN_DC
Input DC voltage to transformer
100
—
400
V
Output voltage of flyback transformer
—
3.6
5
V
OUTPUT CHARACTERISTICS
VOUT
12
IOUT
Output current
—
10
—
mA
FMAX
Desired switching frequency
—
62
—
KHz
ŋ
Targeted efficiency
—
70
—
%
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2.2.2
Transformer Turns Ratio Calculation
The UCC28881 has a 700-V integrated MOSFET, and for the transformer to operate up to 400-V DC input
voltage, the flyback reflected voltage (VR) and the maximum drain-to-source MOSFET voltage(VDS) stress
are decided accordingly.
VR is the voltage across the primary winding when the switching controller IC U1 is turned off. This also
affects the maximum drain-to-source voltage (VDS ) rating of MOSFET integrated in UCC28881. The
maximum drain-to-source voltage (VDS_MAX) is given by Equation 2.
V DS _ MAX = V DC _ IN(MAX ) + V R + V CLAMP
(2)
where:
• VCLAMP is the voltage spike caused by the leakage inductance of the transformer and clamped by the
snubber
• VR is the reflected voltage across transformer primary winding
• VDC_IN(max) is the maximum DC input voltage (400 V) to transformer
Assuming VCLAMP to be around 25% of VDS_MAX, where VDS_MAX is taken to be around 630 V. VR is calculated
as 630 = 400 + VR + 160.
where VR = 70 V
Choosing the VR is a compromise between the primary MOSFET and the secondary rectifier voltage
stress. Setting it too high, by means of a higher turns ratio, would mean a higher VDS_MAX but lower voltage
stress on the secondary diode. Setting it too low, by means of a lower turns ratio, would lower VDS_MAX but
increases the secondary diode stress.
With the highest output voltage being 5 V, the minimum turns ratio required is determined by Equation 3.
VR
N PS =
V OUT + V DIODE
(3)
where:
• NPS is the turns ratio of transformer for a 5-V output
• VOUT is the maximum non-isolated output
• VDIODE is the drop across the secondary rectifier diode, assuming 0.7 V
N PS =
70
= 12.28
(5 + 0.7 )
The actual turns ratio is chosen to be 12.61.
The transformer is designed for 100-V to 400-V DC input voltage, 5-V DC output voltage, and 1-A DC
output current with switching frequency of 62 kHz.
2.2.3
Feedback Component Selection
The feedback threshold for the UCC28881 is 1.03 V. Hence for a output voltage requirement of 3.6 V, the
feedback resistor divider network is selected by Equation 4.
R PULL _ DN
1.03 = 3.6 ´ R PULL _ UP + R PULL _ DN
(4)
To limit the current through the feedback resistor divider network, RPULL_UP shall be chosen around 100 kΩ.
With this value of RPULL_UP, the calculated value of RPULL_DN is 40.2 kΩ.
The final selected value for RPULL_DN is 40.2 kΩ.
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System Design Theory
2.2.4
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VDD Supply and Biasing Capacitor
The supply for operation of the UCC28881 is generated internally and there is no need for an external
voltage source (for example, the auxiliary winding of a flyback converter). Use a capacitance of 100 nF on
the VDD pin to ensure a high-phase margin of the internal 5-V regulator; place this capacitor close to the
VDD pin and GND pins to minimize the series resistance and inductance.
2.2.5
Secondary Rectifying Diode Selection
Output diode reverse voltage or blocking voltage at needed secondary side (VDIODE_BLOCKING) can be
calculated using Equation 5.
V DC _ MAX
V DIODE _ BLOCKING =
+ V OUT
N PS
(5)
For a 3.6-V non-isolated output, the diode blocking voltage is calculated as:
V DIODE _ BLOCKING =
400
+ 3.6 = 36.9 V
12
For this TI Design, a 100-V, 2-A diode is used for rectifying diode on secondary side (part number:
PMEG10020AELRX). A high-current part is used to reduce the voltage drop across the diode.
2.2.6
Output Capacitor Selection
The UCC28881 operates under on/off control. When the FB pin voltage is below internal reference 1 V,
the converter is switching and sending power to the load. When the FB pin voltage is above internal
reference 1 V, the converter shuts off and stops delivering power to the load. Normally, the converter
would operate under frequency control, which means the converter is only enabled one switching cycle
and then disabled. Next switching cycle starts when output voltage decays and the feedback enable the
converter again. This way, the converter appears to operate under variable switching frequency control.
This causes larger output voltage ripple. At lower loads, the switching frequency will be very low and vice
versa. The output capacitor needs to be calculated to reduce the ripple at the necessary operating load
conditions.
However in this end application, the load is not constant and is duty cycled. Also when the load is on, the
peak current requirement is higher than what the power supply can deliver. The input current limiter circuit
limits the input current to the flyback converter. Therefore, the peak current has to be supplied by the
output storage capacitor. This necessitates adequate sizing of the output capacitor based on the peak
current and the on time of the load, assuming the off time of the load is much higher than the on time. The
value of output capacitor can be calculated using Equation 6.
DT
C OUT = I ´
DV DD
(6)
where:
• I is current supplied to the MCU
• ΔT represents the time during which high peak current is supplied to the MCU by the output capacitor
• ΔVDD is the allowed drop in the MCU power supply
At a 5-dBm power level, the CC2650MODA MCU requires peak current of about 10 mA for a duration of
almost 4.7 ms and assuming ΔVDD to be 300 mV.
C OUT = 0.01 ´
0.0047
0.3
For this TI Design, three 47-μF, 10-V DC rated capacitors are used in parallel at the output to supply
required peak current by the CC2650MODA MCU. Two capacitors (C4 and C5) are used at the flyback
output and the other 47-μF capacitor (C9) is present at the output of the LDO (LP5912).
14
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Getting Started Hardware
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3
Getting Started Hardware
3.1
Test Equipments Used to Validate Board
•
•
•
•
3.2
AC power supply: 0 to 130 V
Digital oscilloscope (use isolated channel scope for observing input voltage and current waveform)
61/2 digit multimeter (×4)
Resistive load
Test Conditions
Input Voltage Range
The AC source must be capable of varying between VIN_AC of 93.5-V to 126.5-V AC. Set the input current
limit to 0.1 A.
Output
A rheostat or resistive decade box is connected at the output to evaluate the board. Testing is also done
by connecting the CC2650 wireless module at the output of the TIDA-01097 power supply board.
3.3
Test Procedure
1.
2.
3.
4.
5.
6.
Connect the AC source at the input terminals (Connector J1) of the reference board.
Connect the output terminal (Connector J2) to the resistive box.
Set the position of resistive box to no-load.
Gradually increase the input voltage from 0 V to a voltage of 110-V AC.
Turn on the load to draw current from the output terminals of the converter.
Observe the startup conditions, current limiting, and smooth switching waveforms.
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Testing and Results
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Testing and Results
Two main tests were performed: one connecting TIDA-01097 power supply board output to a resistive
load, and the other one connecting the CC2650MODA wireless module (mounted on TIDA-01097 RF
board).
When the TIDA-01097 power supply board is connected to the CC2650MODA module, the BLE device
monitor sample application was used to transmit data wirelessly.
The test results are divided into multiple sections that cover the test data with resistive load, functional
performance waveforms, and test results with CC2650MODA wireless module.
4.1
Test Data With Resistive Load
For this test, a resistive box is connected at the output terminal of the TIDA-01097 power supply board.
4.1.1
Regulation With Load Variation
This section provides test data for regulation with load variation at the output at a different input AC
voltage.
Table 3. Load Regulation Data at 93.5-V AC Input
VIN_AC(V)
IIN_AC(mA)
IOUT(mA)
VLDO_IN(V)
VLDO_OUT(V)
93.5
0.80
8.920
3.54
3.294
93.5
0.69
8.050
3.56
3.294
93.5
0.60
7.020
3.57
3.294
93.5
0.50
5.710
3.58
3.294
93.5
0.41
4.470
3.59
3.294
93.5
0.31
3.100
3.59
3.295
93.5
0.21
1.600
3.55
3.295
93.5
0.10
0.008
3.57
3.295
Table 4. Load Regulation Data at 110-V AC Input
VIN_AC(V)
16
IIN_AC(mA)
IOUT(mA)
VLDO_IN(V)
VLDO_OUT(V)
110
0.820
10.740
3.55
3.294
110
0.740
10.090
3.57
3.294
110
0.690
9.510
3.58
3.294
110
0.650
8.990
3.59
3.294
110
0.600
8.310
3.59
3.294
110
0.500
6.750
3.60
3.294
110
0.530
7.220
3.60
3.294
110
0.420
5.530
3.61
3.294
110
0.340
4.130
3.61
3.294
110
0.230
2.270
3.60
3.294
110
0.150
0.960
3.59
3.295
110
0.108
0.005
3.59
3.295
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Table 5. Load Regulation Data at 126.5-V AC Input
VIN_AC(V)
4.1.1.1
IIN_AC(mA)
IOUT(mA)
VLDO_IN(V)
VLDO_OUT(V)
126.5
0.80
12.250
3.58
3.294
126.5
0.69
10.840
3.61
3.294
126.5
0.61
9.590
3.61
3.294
126.5
0.50
7.730
3.63
3.294
126.5
0.41
6.150
3.63
3.294
126.5
0.31
4.190
3.63
3.295
126.5
0.20
2.080
3.62
3.295
126.5
0.10
0.006
3.60
3.295
Input Current versus Output Current Variation
Figure 11 shows the variation in input current with a change in output load current at different input AC
voltages.
14
Output Load Current (mA)
12
10
8
6
4
110-V Input Voltage
126.5-V Input Voltage
93.5-V Input Voltage
2
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Input Current (mA)
0.8
0.9
1
D002
Figure 11. Input AC Current versus Output DC Current at Different Input Voltages
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Performance Waveforms
This section contains various waveforms captured at the input side of the TIDA-01097 board.
Input AC
current
Input AC
current
Input AC voltage
Input AC voltage
Figure 12. Input Voltage and Current Waveform at 5.43mA Load at Output With 110-V AC Input
Figure 13. Input Voltage and Current Waveform at 10.15mA Load at Output With 110-V AC Input
Current waveform across
sense resistor of 6.81 NŸ
Figure 14. Current Start-up Waveform at 1.93-mA Load at Output With 110-V AC Input
NOTE: The current waveforms are captured across sense resistor of a 6.81-kΩ resistor, which is
connected in series with the input AC source.
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4.1.3
Efficiency Data for Flyback Configuration
This section provides efficiency data for the flyback power stage as shown in Figure 15.
VDCBUS
100-450VDC
U2
T1
D3
275V
C3
0.15µF
D4
S1J
PGND
TP3
1
6
2
5
3
4
D5
6
IN
4
C4
47μF
EN
C7
1µF
C5
47μF
2
750343332
OUT
NC
PGND
J2
1
PG
3
GND
PAD
5
7
R7
C8
1µF
1
2
3
4
C9
47μF
100k
61300411121
LP5912-3.3DRVR
D6
R5
100k
U1
2
1
3
4
C1
0.1µF
GND
GND
DRAIN
FB
VDD
PGND
4.7V
BZT52C4V7-13-F
PGND
PGND
PGND
PGND
PGND
C6
0.01µF
8
NC
6
HVIN
5
PGND
R6
40.2k
VDCBUS
PGND
UCC28881DR
PGND
Copyright © 2016, Texas Instruments Incorporated
Figure 15. Schematic of Flyback Topology for Testing Efficiency
Table 6. Efficiency Data for Flyback Power Stage
VIN_DC
(V)
IIN_DC
(µA)
PIN_DC
(mW)
IOUT
(mA)
VLDO_IN
(V)
PLDO_IN
(mW)
%
EFFICIENCY
BEFORE LDO
VLDO_OUT
(V)
PLDO_OUT
(mW)
%
EFFICIENCY
WITH LDO
155.5
374
58.16
10.74
3.73
40.07
68.90
3.31
35.55
61.13
155.5
328
51.00
9.16
3.73
34.17
66.99
3.31
30.32
59.45
155.5
296
46.03
8.07
3.73
30.08
65.36
3.31
26.71
58.03
155.5
269
41.83
7.14
3.73
26.60
63.58
3.31
23.63
56.50
155.5
257
39.96
6.75
3.72
25.13
62.88
3.31
22.34
55.91
155.5
240
37.32
6.18
3.72
23.00
61.62
3.31
20.46
54.81
155.5
210
32.66
5.15
3.72
19.13
58.59
3.31
17.05
52.20
155.5
191
29.70
4.47
3.71
16.58
55.84
3.31
14.80
49.82
155.5
175
27.21
3.94
3.71
14.60
53.66
3.31
13.04
47.92
155.5
158
24.57
3.34
3.70
12.36
50.30
3.31
11.06
45.00
155.5
132
20.53
2.45
3.69
9.05
44.07
3.31
8.11
39.51
155.5
114
17.73
1.84
3.69
6.78
38.27
3.31
6.09
34.36
155.5
96
14.93
1.19
3.68
4.38
29.34
3.31
3.94
26.39
155.5
87
13.53
0.90
3.68
3.31
24.47
3.31
2.98
22.02
155.5
79
12.28
0.60
3.68
2.21
18.01
3.31
1.99
16.22
155.5
75
11.66
0.45
3.67
1.65
14.18
3.31
1.49
12.77
155.5
67
10.42
0.20
3.67
0.74
7.12
3.31
0.67
6.42
155.5
65
10.11
0.13
3.67
0.48
4.72
3.31
0.43
4.26
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4.1.3.1
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Efficiency Plot
Figure 16 shows efficiency plotted with a variation in the load current.
80%
70%
Efficiency (%)
60%
50%
40%
30%
20%
10%
After LDO
Before LDO
0
0
2
4
6
8
Output Load Current (mA)
10
12
D001
Figure 16. Efficiency Before and After LDO With Output Load Variation
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4.1.4
UCC28881 Integrated MOSFET Switching Node Waveform
To measure the voltage at the switch node of the converter, a probe with ground spring is used. Due to
the low output current, the UCC28881 is going to operate in discontinuous current mode (DCM).
To show the DCM, Figure 17 provides a good orientation by different states, labeled from A to D where
two resonant oscillations can be observed:
B
C
D
A
Figure 17. Switch Node Voltage Waveform at 10.40-mA Output Load With 110-V AC Input Voltage
•
•
•
•
A: The integrated FET (between the DRAIN pin and GND pin of the UCC28881) is on. As a result, the
VDRAIN can be measured on the drain node, and primary winding current flows through the integrated
FET and rises.
B: The integrated FET goes off. The high-frequency oscillation happened during the initial turn-off
event of integrated FET is due to leakage inductance of the transformer (T1) and parasitic capacitance
present between drain node and ground.
C: The integrated FET is completely turned off now and the secondary side diode (D8) gets forward
biased, and the energy is transferred from secondary winding of transformer (T1) to the output load.
D: Oscillation 2 happens when the secondary winding energy declines to zero. During this time, both
windings of transformer (T1) are open, thus, primary winding inductance of transformer (T1) resonates
with the parasitic capacitance at the drain node.
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4.1.5
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Flyback Power Supply Output Ripple
Figure 18 and Figure 19 show the DC voltage captured at the 3.3-V DC output (after the LDO) and before
the LDO at different load current.
Voltage before LDO
Voltage before LDO
Voltage after LDO
Voltage after LDO
Figure 18. DC Voltage Before and After LDO at 1.09-mA
Load Current With 110-V Input AC Voltage
4.1.6
Figure 19. DC Voltage Before and After LDO at 10.21-mA
Load Current With 110-V Input AC Voltage
Start-up and LDO Power Good Waveform
This section provides start-up and power good waveform at a 2.33-mA output load.
3.3-V DC output after LDO
PG pin of LDO
Figure 20. Start-up and Power Good With 110-V AC Input and 3.3-V/2.33-mA DC Output
NOTE: The rise time of the 3.3-V DC output is around 290 ms, which is highlighted in Figure 20.
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4.2
Test With CC2650MODA Wireless Module
For this test, the TIDA-01097 RF board with a CC2650MODA module mounted on it has been connected
at the output of the TIDA-01097 power supply board.
4.2.1
Prerequisites
To
•
•
•
•
4.2.2
test and obtain the results of this TI Design, the following tools were used:
AC power supply to power up the board
Isolated CRO to capture the current consumption waveforms
To measure average power consumption for BLE, the following hardware are required:
❏ TIDA-01097
❏ INA216A3 (voltage current shunt monitor)
❏ CC2650 LaunchPad™
A Windows® PC installed with:
❏ BLE Stack for CC2650 version 2.0.2.0.31 or higher
❏ Code Composer Studio™ version 6.1.2.00015 or higher
❏ BLE Device Monitor
❏ Smart RF Studio 7
PC Host and Test Board Preparation
Follow these steps to set up firmware with the TIDA-01097 and measure current consumption of the
CC2650MODA wireless module during various modes such as advertisement, connection, and periodic
data exchange like notifications.
PC Host Preparation
Test Board Preparation
1. Install CCS with version mentioned in
prerequisite section.
2. Install BLE Stack for the CC2650.
3. Import Host Test App and Stack from the TI
resource explorer in CCS.
Ble_sdk_2_02_00_31 → examples →
cc2650lp → host_test
4. Connect the CC2650 LaunchPad to the PC.
5. Flash the host_test stack and then the app
in the CC2650 LaunchPad
6. Terminate the debugger section and open
the BLE Device Manager.
7. Enter the correct serial port mounted by the
CC2650 LaunchPad in the BLE Device
Monitor and confirm it mounting on the BLE
Device Monitor.
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1. Connect the TIDA-01097 RF board with the
CC2650MODA mounted on it to the CC2650
LaunchPad on the external target jumper.
Remember to remove all jumpers from the
XDS110 and the CC2650 LaunchPad.
2. Open CCS and import the simple BLE
peripheral stack and app project in the
workspace from the TI resource explorer:
Ble_sdk_2_02_00_31 → examples →
cc2650em → simple_peripheral
3. In preprocessor directives, add
CC2650DK_5XD and remember to remove
CC2650DK_7ID. Build both the projects of
stack and app.
4. Flash the simple_peripheral stack and then
app in the TIDA-01097 RF board.
5. Terminate the debugger section.
6. Connect the AC power to the TIDA-01097
power supply board.
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4.2.3
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Test Setup
Figure 21 shows the hardware interconnections and wireless connections required for measuring current
consumption of the CC2650MODA wireless module when the TIDA-01097 RF board is connected to the
TIDA-01097 power supply board.
Isolated oscilloscope for capturing the
INA216 A3 output waveforms for
CC2650MODA current consumption
Input AC power
source
BLE Device Monitor
App
CC2650MODA mounted on the
RF board with the INA216A3 for
current measurement
TIDA-01097
BLE connection for the
CC2650MODA working
and configuration
CC2650 /DXQFK3DGŒ
acting as host as well as
flash programmer
PC running BLE device
monitor to interface and
control the CC2650
LaunchPad and to connect
to the CC2650MODA
Figure 21. Test Setup to Measure Current Consumption of CC2650MODA
Figure 22 shows the assembly of the TIDA-01097 RF board on the TIDA-01097 power supply board with
the CC2650MODA wireless module mounted on it.
Figure 22. TIDA-01097 RF Board Connected to TIDA-01097 Power Supply Board
NOTE: For easy and accurate current measurement, the INA216 device is used at the output of
LDO LP5912. As this may not needed in the final end application PCB, this is shown as DNP
in the schematic.
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4.2.4
Test Procedure
Figure 23 shows the test flow followed to test current consumption of the CC2650MODA module:
TIDA-01097
Prepare test board
Prepare PC host
Connect oscilloscope
probes to test points
placed before LDO
input and after LDO
output at the output
of INA216A3
The INA216A3 is being used to measure
the typical low current consumption values
during various operations of the
CC2650MODA like advertisement and
connection and periodic data exchange
like notifications.
Power up the TIDA01097 main board
Capture waveform on
oscilloscope
Perform a SCAN in
BLE device monitor
at PC
As soon as the TIDA-01097 powers up,
the CC2650MODA starts sending the
BLE advertisement beacon on the
configured TX power level on all the
advertisement channels.
See Figure 23 and Figure 24.
Once the
CC2650MODA
appears in the
discovered object list,
select it and connect it
The discovered node of the
CC2650MODA will appear as Simple BLE
peripheral with its MAC address and RSSI
value of received signal strength. Use the
RSSI value to confirm the TX power levels
configuration or change provided the
TIDA-01097 and CC2650LP are kept at
the same distance.
On successful
connection, observe all
characteristics and
attributes appearing on
the right side of the
BLE device monitor
window
Individually read the attributes of the
characteristics. Enable the notification by
writing the value 01:00 in characteristic 4,
also prompted by the BLE device monitor.
This enables periodic data exchange after
every 3 seconds apart from the
connection refresher process by
the BLE stack.
Capture waveform on
oscilloscope
See Figure 25 and Figure 26.
Repeat the process for
TX power configured to
0 dBm and 5 dBm. By
default, the BLE stack
has TX power
configured to 0 dBm
Change the TX power in the BLE stack in
the code file ble_user_config.c by
updating the value of the
DEFAULT_TX_POWER macro as per the
txPowerTable array so the values come
as 7(0 dBm) and 12 (5 dBm).
Figure 23. Test Flow to Test Current Consumption of CC2650MODA
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4.2.5
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Test Results
This section contains waveforms captured at the output of the INA216A3 when the CC2650MODA module
is transmitting at different power levels in advertisement and connected mode.
4.2.5.1
CC2650 Advertisement Event
Figure 24 and Figure 25 show the waveforms of output voltage of the LDO and output voltage of the
INA216A3 (connected after the LDO) when the CC2650MODA is transmitting at power level of 0 dBm and
5 dBm, respectively.
3.3-V DC output
3.3-V DC output
Output of INA216
Output of INA216
Figure 24. Output Voltage of LDO and INA216A3 Under
110-V AC Transmitting at 0 dBm in Advertisement Mode
Figure 25. Output Voltage of LDO and INA216A3 Under
110-V AC Transmitting at 5 dBm in Advertisement Mode
A sense resistor of 3.09 Ω is connected at the input of the INA216A3. The current consumption of the
CC2650MODA module can be calculated by capturing the maximum voltage across output of the
INA216A3. The current consumption is calculated by Equation 7.
Output voltage of INA216A3
Current consumption (I) =
(Sense resistor ´ Gain of INA216A3 )
(7)
For example, from Figure 24, the peak-to-peak output voltage of the INA216A3 connected after the LDO is
2.12 V.
I =
2.12
= 6.86 mA
(3.09 ´ 100 )
So, the current consumption of the CC2650MODA wireless module comes out to be 6.86 mA peak when it
is transmitting at power level of 0 dBm in advertisement mode.
Similarly, the current consumption of the CC2650MODA module can be calculated by measuring the
output voltage of the INA216 in connected and periodic data exchange operations operating at different
power levels.
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4.2.5.2
Connected and Periodic Data Exchange Event
Figure 26 and Figure 27 show the waveforms of the output voltage of the LDO and output voltage of the
INA216A3 (connected after the LDO) when the CC2650MODA is transmitting and receiving at power level
of 0 dBm and 5 dBm, respectively.
3.3-V DC output
3.3-V DC output
Output of INA216
Output of INA216
Figure 26. Output Voltage of LDO and INA216A3 Under
110-V AC at 0 dBm in Connected and Data Exchange
Mode
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Figure 27. Output Voltage of LDO and INA216A3 Under
110-V AC at 5 dBm in Connected and Data Exchange
Mode
<125-µA Standby, High-Efficiency Power Supply Reference Design for
Neutral-less Wireless Lighting Controls
Copyright © 2016, Texas Instruments Incorporated
27
Design Files
5
Design Files
5.1
Schematics
www.ti.com
To download the schematics, see the design files at TIDA-01097.
5.2
Bill of Materials
To download the bill of materials (BOM), see the design files at TIDA-01097.
5.3
5.3.1
PCB Layout Recommendations
Layout Prints
To download the layer plots, see the design files at TIDA-01097.
5.4
Altium Project
To download the Altium project files, see the design files at TIDA-01097.
5.5
Gerber Files
To download the Gerber files, see the design files at TIDA-01097.
5.6
Assembly Drawings
To download the assembly drawings, see the design files at TIDA-01097.
6
Software Files
To download the software files, see the design files at TIDA-01097.
7
References
1. EDN Network, Circuit achieves constant current over wide range of terminal voltages, Donald
Boughton, Jr, International Rectifier, Orlando, FL; Edited by Martin Rowe and Fran Granville
2. Acuity Brands, Impact of NEC 2011 Section 404.2(C) on Application of Occupancy Sensors, Dave
Behnke
3. Texas Instruments, 100-V to 450-V DC, 5-W, 80% Efficiency at 1 W, Auxiliary Supply Reference
Design for AC-DC Power Converters, TIDA-00708 Design Guide (TIDUBK7)
7.1
Trademarks
All trademarks are the property of their respective owners.
28
<125-µA Standby, High-Efficiency Power Supply Reference Design for
Neutral-less Wireless Lighting Controls
Copyright © 2016, Texas Instruments Incorporated
TIDUCE6 – December 2016
Submit Documentation Feedback
About the Authors
www.ti.com
8
About the Authors
SEETHARAMAN DEVENDRAN is a systems architect at Texas Instruments, where he is responsible for
developing reference design solutions for the industrial segment. Seetharaman brings to this role his
extensive experience in analog and mixed signal system-level design expertise. Seetharaman earned his
bachelor’s degree in electrical engineering (BE, EEE) from Thiagarajar College of Engineering, Madurai,
India.
SURYA MISHRA is a systems engineer at Texas Instruments where he is responsible for developing
reference design solutions for the Lighting, Industrial Segment. Surya earned his bachelor of electronics
and communication engineering from the Motilal Nehru National Institute of Technology (MNNIT),
Allahabad.
ABHED MISRA is a system applications lead at Texas Instruments, where he takes care for LPRF
product portfolio support for entire India and is also responsible for doing reference designs for LPRF
products. He received his master of technology in communication engineering from NIT, Jaipur, India.
TIDUCE6 – December 2016
Submit Documentation Feedback
<125-µA Standby, High-Efficiency Power Supply Reference Design for
Neutral-less Wireless Lighting Controls
Copyright © 2016, Texas Instruments Incorporated
29
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