Power supply fault protection circuit with primary side shutdown and restart

• US 9,350,253 B1
• Filed: 09/24/2015
• Issued: 05/24/2016
• Est. Priority Date: 09/24/2015
• Status: Active Grant

• Current Assignee: ABL IP Holding LLC (Acuity Brands, Inc.)
• Original Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Inventors: Zielger, Markus, Xiao, Peng
• Primary Examiner(s): Tran, Anh
• Application Number:
  US14/864,824
• Time in Patent Office: 243 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: H02M 1/0003 Details of control, feedback or regulation circuits
• CPC Class Codes: H02M 3/33523 with galvanic isolation between input and output of both the power stage and the feedback loop
• CPC Class Codes: H05B 45/385 using flyback topology
• CPC Class Codes: H05B 47/20 Responsive to malfunctions or to light source life; for protection
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

Abstract

Fault protection circuitry and methodologies for isolated power supply topologies are provided. The circuitry is configured to shut down the primary side of the supply in case of a system fault, while keeping the secondary side circuit running, thus offering flexibility for restarting upon clearing of the fault. A lighting driver thus configured with safety isolation and a secondary side microcontroller or other control circuitry, is configured so that the circuit can shut down the primary side in response to system fault detection, while keeping the secondary microcontroller running from an energy storage circuit (e.g., bulk capacitor in parallel with load). The driver operation can resume with a controlled timing if the fault is cleared. The number of restarts may be limited, and/or a timer may be used to space restarts. The driver may be used with loads other than lighting-based loads, as will be appreciated.

Claims

1. A fault protection system for a power supply having a primary side and secondary side separated by a galvanic barrier, the system comprising:

a fault detection circuit configured to declare a fault mode in response to fault detection;

an isolated control circuit configured to deliver a shutdown signal from the secondary side to the primary side without violating the galvanic barrier, in response to an indication of fault from the fault detection circuit;

an auxiliary power circuit having an output node from which current to the fault detection circuit is provided during the fault mode; and

a switch circuit configured to connect the isolated control circuit to the auxiliary power circuit during the fault mode, so that an auxiliary current can flow through the isolated control circuit to the output node of the auxiliary power circuit.

2. The fault protection system of claim 1, wherein the secondary side includes a storage circuit configured to be electrically connected in parallel with a load drivable by the power supply, the auxiliary current being delivered from the storage circuit to the isolated control circuit during the fault mode.

3. The fault protection system of claim 2, wherein the storage circuit comprises a bulk capacitor.

4. The fault protection system of claim 1, wherein the fault detection circuit is further configured to clear the fault mode, thereby ceasing delivery of the shutdown signal to the primary side, which in turn allows the primary side of the power supply to restart.

5. The fault protection system of claim 4, wherein the fault detection circuit clears the fault mode in response to at least one of expiration of a shutdown timer, a successful fault mitigation, and a restart counter being less than a permanent shutdown threshold value.

6. The fault protection system of claim 5, wherein the fault detection circuit is configured to enter a power conserving mode while the shutdown timer is running.

7. The fault protection system of claim 5, wherein the fault detection circuit comprises a microcontroller.

8. The fault protection system of claim 1, wherein the isolated control circuit comprises an opto-coupler having a light emitting diode and a photo-transistor, the light emitting diode configured to pass the auxiliary current to the output node of the auxiliary power circuit via the switch circuit, and the photo-transistor configured to deliver an indication of the shutdown signal to a primary side switch circuit capable of shutting down the primary.

9. The fault protection system of claim 1, wherein the auxiliary power circuit further comprises a Zener diode configured to provide a desired voltage at the output node.

10. The fault protection system of claim 9, wherein the auxiliary power circuit further comprises a current limiting circuit, configured so that only a pre-defined amount of current can flow to the output node, the predefined amount being within 10% or less of the auxiliary current.

11. The fault protection system of claim 10, wherein the current limiting circuit comprises a second Zener diode in parallel with a resistor.

12. The fault protection system of claim 1, wherein the switch circuit comprises a first transistor that turns on in response to an output signal from the fault detection circuit and a second transistor that turns on in response to the first transistor turning on, the second transistor allowing the auxiliary current to flow from the isolated control circuit to the output node.

13. A lighting driver, comprising:

a primary side and a secondary side separated by a galvanic barrier, wherein the secondary side includes a storage circuit configured to be electrically connected in parallel with a light source configured to be driven by the lighting driver;

a fault detection circuit configured to declare a fault mode in response to fault detection, and to clear the fault mode in response to at least one of expiration of a shutdown timer, a successful fault mitigation, and a restart counter being less than a permanent shutdown threshold value;

an isolated control circuit configured to deliver a shutdown signal from the secondary side to the primary side without violating the galvanic barrier, in response to an indication of fault mode from the fault detection circuit;

an auxiliary power circuit having an output node from which current to the fault detection circuit is provided during the fault mode; and

a switch circuit configured to connect the isolated control circuit to the auxiliary power circuit, so that an auxiliary current can flow from the storage circuit through the isolated control circuit to the output node of the auxiliary power circuit, the switch circuit comprising a first transistor that turns on in response to the shutdown signal from the fault detection circuit and a second transistor that turns on in response to the first transistor turning of, the second transistor allowing the auxiliary current to flow from the isolated control circuit to the output node.

14. The lighting driver of claim 13, wherein the fault detection circuit is configured to enter a power conserving mode while the shutdown timer is running.

15. The lighting driver of claim 13, wherein the isolated control circuit comprises an opto-coupler having a light emitting diode and a photo-transistor, the light emitting diode configured to pass the auxiliary current to the output node of the auxiliary power circuit via the switch circuit, and the photo-transistor configured to deliver an indication of the shutdown signal to a primary side switch circuit capable of shutting down the primary.

16. The lighting driver of claim 13, wherein the auxiliary power circuit further comprises a Zener diode configured to provide a desired voltage at the output node, and a current limiting circuit having a second Zener diode in parallel with a resistor and configured so only a pre-defined amount of current can flow to the output node, the predefined amount within 10% or less of the auxiliary current.

17. A method of powering a load using a power supply having a primary side and secondary side separated by a galvanic barrier, the method comprising:

declaring a fault mode, via a fault detection circuit, in response to fault detection;

delivering, via an isolated control circuit, a shutdown signal from the secondary side to the primary side without violating the galvanic barrier, in response to a declared fault mode from the fault detection circuit;

providing an auxiliary power circuit having an output node from which current to the fault detection circuit is provided during the declared fault mode;

connecting, via a switch circuit, the isolated control circuit to the auxiliary power circuit, so that an auxiliary current can flow through the isolated control circuit to the output node of the auxiliary power circuit, the switch circuit comprising a first transistor that turns on in response to the shutdown signal and a second transistor that turns on in response to the first transistor turning off, the second transistor allowing the auxiliary current to flow from the isolated control circuit to the output node.

18. The method of claim 17, further comprising:

clearing the fault mode in response to at least one of expiration of a shutdown timer, a successful fault mitigation, and a restart counter being less than a permanent shutdown threshold value.

19. The method of claim 18, further comprising:

entering the fault detection circuit into a power conserving mode while the shutdown timer is running.

20. The method of claim 18, wherein the secondary side includes a storage circuit configured to be electrically connected in parallel with a load drivable by the power supply, the auxiliary current being delivered from storage circuit to the isolated control circuit during the fault mode.