Can I use TPS92210 for LED Driver to get output power of 65W ( 90V, 0.72 A). Operating range of 90V - 265V AC ?

Have you looked at any of the waveforms such as the drain?  What switching frequency is it operating at?  How did you scale up the design for higher power?

Dear Irwin,

The switching Freq is 130KHz.

We have placed 30 LEDs in Series and 6 such Parallel lines. ( Total 180 LEDs).  The Output Voltage required is 90V and the desired Output current of 700mA. 

For increasing the Wattage, we have modified the Current Sensing circuit of our well set design of 45W LED Driver, that we are already using comfortably. 

We have also already designed OVP using TLV809K33 IC for Cut off above 270V.

Request your help, in designing the Transformer for 65W and any other modifications that have to be made . Also acceptable Input Voltage Range is 150V to 270V.

As much as possible, we want to stick to TPS92210 as we have well set design and do not want to go for another IC for 65W.

The design with ETD29 will be highly appreciated. We are also open for design with PQ Series Core.

Dear Irwin,

We have used the design forwarded by TI, Banglore, India - PMP3661_REVB for 45W Driver Design.

The Peak Input Current after which the Power Starts to Fall Off is as under:

For 45W Design : 440mA at 100V AC Input

For 65W Design : 410mA at 150V Ac Input

Please find below the Magnetic Data for the above Schematic that we are using for 45W comfortably.

Magnetic Details for PMP3661:

Electrical requirements
Leakage Inductance (Pin1-2) - 53H (max) with all other windings/pins shorted

 Insulation Voltage – Between 1 - 5 pins shorted and to pins 9 & 10 shorted together
– 1500V AC for 1min

Transformer Construction –

Winding Procedure:
Start with half primary (W1) starting at Pin 2 and end at pin 5 in one layer
Basic insulation
Wind bias (W2) in one layer spreading uniformly across bobbin width, start at 4, end at 3
Reinforced Insulation
Wind secondary (W3) in two layers, start at pin 9, end at 10.
Reinforced Insulation
Wind half primary (W1) continuing at pin 5 and ending at pin 1 in one layer
Reinforced Insulation
Wind secondary bias (W4) in one layer spreading uniformly across bobbin width, start at 8, end at 7
Reinforced Insulation
Gap core suitably (approximately 0.25mm on each side limbs) to get required primary inductance
Bond the core to avoid audible noise
Vacuum impregnate with varnish
Cut-off pin 5 without damaging the termination on it.

Special requirements
Use 0.5mm Triple Insulated Wire for secondary winding, if UL/EN safety isolation is
required.

The above data is provided by 

Texas Instruments India,
Bagmane Tech Park, CV Raman Nagar,
Bangalore -560093

Based on the above, please help us with the Transformer Design required for 65W ( for the Output of 90V, 720mA). 

Input Voltage 160V - 270V AC., 50Hz.

External MOSFET used in 45W Design is 5N90.

Preferably consider Core Epcos ETD29/16/10 or any suitable core from PQ32-20.

Hello,

So this is what I would try to start with for PQ3220:

W1  34 turns (half (17 turns) on first layer, half (17 turns) on second to last in series)

Split primary first layer 17 turns 26 gauge magnet wire end to unused pin (to series the primary after second half wound)

basic insulation

W2  three turns 30 to 36 gauge magnet wire evenly spaced along width of winding area

reinforced insulation (or use of triple insulated wire)

W3  3X 14 turns 28 gauge triple insulated wire.  (three windings in parallel that are 14 turns of 28 gauge wire)

reinforced insulation

Finish W1, 17 turns 26 gauge magnet wire starting from unused pin from first half of primary winding, W1

reinforced insulation

W4 four turns triple insulated 30 to 36 gauge wire evenly spaced across the winding area

AL of PQ3220 bobbin set ground to 250nH AL, overall inductance of N^2*AL approx 290 uH

The pinout is your choice for layout and optimal transformer build.  Due to the narrow winding window use of triple insulated wire may be the only way to make this.

This should give about 300 mohm of DC resistance for the primary and about 70 mohm of DC resistance for the secondary.

ratio should be:  (34:3:14:4) for (W1:W2:W3:W4)  This keeps the ratio for output and two bias supplies the same (3:14:4) which is half of your present transformer (6:28:8).  The primary to secondary ratio went from 1:1 to 2.43:1.  This means the output diode, leakage clamp and MOSFET need to be check for rating.  there will be 90V times 2.43 reflected instead of 90v times 1 (219V instead of 90V).

At higher power you may also have to deal with more leakage energy increasing the bias voltages.  This can be fixed by resistive loading, more series resistance with the bias regulating diodes and/or linear regulating the outputs of the bias windings.

Thanks,