300 Watts ET tear down

300 Watt Electronic Transformer

Manufacturer: Relco Italy Model: DINO CC300 S Power: Min 100 W , max 300W 230 - 240 V AC input 12 V DC output Double output from both sides of the housing

M1

L2

Top view
M4 Q4, Q5

M4

Q3,Q2

L3

L4

Center tap on secondary

Q6,Q7 M3 M1: 230 VAC, 60 Hz input M3, M4: 12 V DC output L3: Output transformer with center tap secondary

Bottom view
Q6
Q7
Gate drive circuit for Q6,Q7

Gate drive circuit for Q4,Q5

Q5 Q4

12 V DC output (M4) 12 V DC output (M3) Output transformer input Transformer output

IR2161S

Diode bridge

Input terminals, 230 V AC

Schematic

A clear schematic with components values visible has been drawn in Visio.

Output Transformer

Litz wire secondary

Primary:

2 parallel wires of 0.74 mm 60 Turns, Total: 120 turns

Secondary: Center-tap double output. Litz wire made up of 80 strands of 0.11mm wire 3 turns of 4 parallel Litz wire wound on each winding Total: 12 turns Core: EE55 core

Other magnetic components

L1 : 29 turns of 0.48 mm wire OD: 14.34 ID: 8.03 Height: 2.34 green ferrite core L2: 140 turns of 0.67 mm OD: 24.23 ID: 13.97 Height: 8.22 yellow core L4: 8 turns of 2.4 mm OD: 26.73 ID : 14.53 Height: 11.38

IC 2161S
Very different circuit from conventional ET -- No saturable transformer. -- No DIAC to initially start the circuit operation. Everything taken care of by International Rectifier IC 2161S

Source: IR product datasheet

Understanding basic IC operation - Modes

Under-voltage lockout mode When the chip VCC is below threshold. Guarantees that IC is fully operational before HO and LO are activated. RS, RD, CD - critical design components. Charge pump(Voltage doubler) connected to circuit for VCC after startup. DB and CB are for supplying power to high side driver circuit.

Modes of operation

Soft-start mode Inrush current under cold filament condition can trigger shut down protection. The frequency is kept high (133kHz) when IC just starts oscillating - this allows less voltage, less current in the lamp which eases the inrush current. CSD connected to soft-start circuit.

Modes of operation

Run Mode ( Voltage compensation mode). Frequency variation required to compensate the output voltage at varying load. CSD connected to Voltage compensation circuit. Load current sensed by RCS (at the source of Q2) and reflected as voltage at CSD. VSD = 5V at full load and 0V at no load. In run mode, Oscillator frequency varies from 34kHz at full load to 70kHz at zero load.

Typical waveforms
VCC pin voltage

CSD voltage
At 100 W 0 to 5 V in soft-start mode in 0.264 sec. In run mode, average value = 0.911 volt

Soft-start mode for 0.264 sec

Run mode

CSD voltage
At 150 W 0 to 5 V in soft-start mode in 0.292 sec. In run mode, average value = 1.78 volt

Soft-start mode for 0.264 sec

Run mode

CSD voltage
At 300 W (full load) 0 to 5 V in soft-start mode in 0.0428 sec. In run mode, average value = 4.69 volt

Soft-start mode for 0.0428 sec

Transition from soft-start mode to Run mode

Run mode

Frequency variation with load

Load (W) 10 20 50 100 150 200 300

Frequency (kHz) 69.44 68.49 63.69 59.8 55.55 48 34

Soft-start mode waveform

Input waveform transformer switched at high frequency initially

At 200 W load, initial frequency = 125 kHz

At run mode, frequency reduces to 48 kHz

Input voltage to transformer

High frequency ( 125 kHz ) initially due to soft-start