Design Example Report Title 30W Adapter using TOP245Y Specification Input: 90 – 265 VAC Output: 9.7 V / 3.0 A Application Portable DVD Author Power Integrations Applications Department Document Number DER-95 Date September 12, 2005 Revision 1.0 Summary and Features • • • • Low cost solution for 30 7W adapter EER28 core Small common mode choke Small X-cap The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 Table Of Contents 1 2 3 4 Introduction................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic................................................................................................................... 6 Circuit Description ...................................................................................................... 7 4.1 Input EMI Filtering ............................................................................................... 7 4.2 Reduced current limit .......................................................................................... 7 4.3 Output Rectification ............................................................................................. 7 4.4 Output Feedback................................................................................................. 7 5 PCB Layout ................................................................................................................ 8 6 Bill Of Materials .......................................................................................................... 9 7 Transformer.............................................................................................................. 10 7.1 Transformer Diagram ........................................................................................ 10 7.2 Electrical Specifications..................................................................................... 10 7.3 Materials............................................................................................................ 10 7.4 Detailed copper shield....................................................................................... 11 7.5 Transformer Construction.................................................................................. 11 7.6 Winding Instructions .......................................................................................... 11 8 Transformer Spreadsheets....................................................................................... 12 9 Performance Data .................................................................................................... 14 9.1 Efficiency........................................................................................................... 14 9.2 No-Load Input Power Integrations..................................................................... 14 9.3 Output regulation............................................................................................... 15 9.3.1 Line regulation............................................................................................ 15 9.3.2 Load regulation (taken at the end of the output cable) ............................... 15 9.4 Thermal Performance........................................................................................ 15 9.5 Maximum output current.................................................................................... 16 10 Waveforms............................................................................................................ 16 10.1 Drain Voltage, Normal Operation ...................................................................... 16 10.2 Output Voltage Start-up Profile ......................................................................... 16 11 Output Ripple Measurements ............................................................................... 17 11.1.1 Ripple Measurement Technique ................................................................ 17 11.1.2 Measurement Results ................................................................................ 18 12 Loop performance................................................................................................. 19 13 Conducted EMI ..................................................................................................... 20 14 Revision History.................................................................................................... 21 The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Page 2 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 Important Notes: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolated source to provide power to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built. Page 3 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 1 Introduction This document is an engineering report describing a single output 30 W power supply utilizing a TOP245Y. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. Figure 1 – Populated Board Page 4 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 2 Power Supply Specification Description Input Voltage Frequency No-load Input Power (230 VAC) Outputs Voltage Current Efficiency Symbol Min Typ Max Units Comment VIN fLINE 90 47 265 64 1.0 VAC Hz W 2 Wire – no P.E. 50/60 VDC IO 9.7 3.0 VDC A η 81 % Measured at POUT (30 W), 25 oC Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Ambient Temperature Page 5 of 22 TAMB 0 40 o C Free convection, sea level Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 3 Schematic Figure 2 – Schematic Page 6 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 4 Circuit Description The schematic in Figure 2 shows an off-line flyback converter using the TOP245Y. The circuit is designed for 90 VAC to 265 VAC input and provides an isolated 9.7 V, 3.0 A continuous output. 4.1 Input EMI Filtering Conducted EMI filtering is provided by pi formed filter C7, C4, L1, The switching frequency jitter feature of the TOPSwitch-GX family allows the use of a small, low cost common mode choke for L1. To keep the peak DRAIN voltage acceptably below the BVDSS (700V) of U1, diode D2, C5, R1 and R3 form a primary clamp. This network clamps the voltage spike seen on the DRAIN due to primary leakage inductance. Diode D3 and capacitor C8 provide rectified and filtered bias supply for U1. 4.2 Reduced current limit Resistor R4, R6, R9 and R13 are used to set the maximum current limit for both high line and low line. R2 is used for input undervoltage lockout (UVLO). 4.3 Output Rectification The secondary of T1 is rectified and filtered by D4, C1 & C3. Post filter choke L2 and C15 provide additional high frequency filtering. 4.4 Output Feedback DC feedback to the output voltage regulator error amplifier (U3) comes from a voltage divider network R8 and R16. The center point of this network is tied to the 2.5 V REF pin of U3. Capacitor C11 and resistor R12 roll off the high frequency gain of U3 while R5 sets the overall gain. C9 is a “soft finish” capacitor to eliminate output over shoot during start up. Page 7 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 5 PCB Layout Figure 3 – Printed Circuit Layout Note: R18 and C17 are not shown in this layout. They are added onto the bottom of the board. Page 8 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 6 Bill Of Materials 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Page 9 of 22 2 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 C1,C3 C9,C12 C5,C13 C6 C7 C4 C8 C10,C11 C15 C16 C17 D1 D2 D3 D4 D5 F1 L1 L2 R1 R2 R3 R4,R6,R9 R5 R7 R8 R10 R11 R12 R13 R16 R17 R18 T1 U1 U2 U3 1000 uF, 16V 47 uF, 16V 1 nF 1.0 nF 33 uF, 400V 47 uF, 400V 22 uF 100 nF 100 uF 10 nF 2.2 nF 2KBP06M 1N4007GP BAV20 MBR1060 Red 2 A 6 mH 3.3 uH 100 k 2.0 M 100 2.4 M 180 3 k 28 k 220 6.8 1.2 k 11.3 k 9.53 k 22 1.0 K EER28 TOP245Y PC817A TL431 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 7 Transformer 7.1 Transformer Diagram 11 3 WD#4 14T #24 Primary 3T # 26X5 TIW Secondary 10 2 2 WD#2 WD#3 14T #24 Primary 5 4T #26X4 4 WD#1 Bias 6 7.2 7.3 Electrical Specifications Electrical Strength 60Hz 1minute, from Pins 1-6 to Pins 7-12 Primary Inductance All windings open (Pin 4 to Pin 3) Resonant Frequency. All windings open (Pin 4 to Pin 3) Primary Leakage Pins 10-11 shorted Inductance. (Pin 4 to Pin 3) Materials Item [1] [2] [3] [4] [5] [6] [7] [8] Page 10 of 22 3000 V ac 600 uH +/- 5% at 132 KHz 900 KHz (Min.) 4 uH Max. Description Core: PC40EER28-Z, TDK or equivalent Gapped for AL of 765 nH/T2 Bobbin: Horizontal 12 pin Magnet Wire: #24 AWG Magnet Wire: #26 AWG Copper, 1 mil thick, 10 mm wide and 12.6 mm wide Triple Insulated Wire: #26 AWG. Tape: 3M 1298 Polyester Film, 2.0 mils thick, 10.6 mm wide and 16.0 mm wide Varnish Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 7.4 30 W Adapter for Portable DVD Detailed copper shield Wire 7.5 September 12, 2005 Tape Copper Transformer Construction Bally band Tape Copper Foil WD#4 ½ Primary 3 2 3 9, 10 Margin Tape 11, 12 WD#3 Secondary 3 2 WD#2 ½ Primary 4 Tape 5 WD#1 Bias 6 7.6 Winding Instructions WD1 Bias Winding Insulation WD#2 ½ Primary winding Insulation Copper Foil [10 mm wide] Insulation WD #3 Secondary Winding Insulation Copper Foil [10 mm wide] Insulation Page 11 of 22 Primary pin side of the bobbin oriented to left hand side. Start at Pin 11 temporally wind 4 turns with 4 wires of item [4] parallel from right to left. Wind with tight tension. Finish on pin 6. Flip the starting lead over to pin 5. 4 Layers of tape [7, 10.6 mm wide] for insulation. Start at pin 4, wind 14 turns of item [3] from left to right. Finish at pin 2 1 Layers of tape [7, 10.6 mm wide] for insulation. Using prepared copper foil in 7.4, start at Pin 3 wind 1 turn. Apply insulation tape of [7, 10.6 mm wide] before the end to avoid short circuit. 1 Layers of tape [7, 10.6 mm wide] for insulation. Start at pin 11 and 12, wind 3 turns of item [6] with 5 wire parallel. from right to left. Wind uniformly, in a single layer across entire bobbin evenly. Finish on pin 9, 10. 1 Layers of tape [7, 10.6 mm wide] for insulation. Using prepared copper foil in 7.4, start at Pin 3 wind 1 turn. Apply insulation tape of [7, 10.6 mm wide] before the end to avoid short circuit. 1 Layers of tape [7, 10.6 mm wide] for insulation. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 WD#4 ½ Primary winding Insulation [16 mm wide] Core Assembly Balley band [12.6 mm wide] Varnish 30 W Adapter for Portable DVD September 12, 2005 Start at pin 2, wind 14 turns of item [3] from left to right. Finish at pin 3 3 Layers of tape [7] for insulation. Assemble and secure core halves. Put one turn of copper contacting the core. Leave 22 AWG wire 50mm long for being connected to primary ground. Varnish 8 Transformer Spreadsheets ACDC_TOPSwitchGX_03 INPUT INFO 2204; Rev.1.9; Copyright Power Integrations Inc. 2004 ENTER APPLICATION VARIABLES VACMIN 90 265 VACMAX 50 fL VO 10 30 PO 0.8 n Z 0.5 15 VB 3 tC CIN INFO OUTP OUTP UNIT UT UT 80 TOP_GX_FX_032204.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Volts Volts Hertz Volts Watts Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Volts Bias Voltage mSeco Bridge Rectifier Conduction Time Estimate nds uFarad Input Filter Capacitor s ENTER TOPSWITCH-GX VARIABLES TOP-GX TOP24 Univer 115 Doubled/230V 5 sal Chosen Device TOP24 TOP24 Power Power 60W 85W 5 5 Out Out 0.72 External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI KI <1.0 for lower ILIMIT) 1.166 1.166 Amps Use 1% resistor in setting external ILIMIT ILIMITMIN ILIMITMAX 1.426 1.426 Amps Use 1% resistor in setting external ILIMIT Frequency (F)=132kHz, F Full (F) frequency option - 132kHz (H)=66kHz 13200 13200 Hertz TOPSwitch-GX Switching Frequency: Choose between fS 0 0 132 kHz and 66 kHz 12400 12400 Hertz TOPSwitch-GX Minimum Switching Frequency fSmin 0 0 14000 14000 Hertz TOPSwitch-GX Maximum Switching Frequency fSmax 0 0 97 Volts Reflected Output Voltage VOR 10 Volts TOPSwitch on-state Drain to Source Voltage VDS 0.5 Volts Output Winding Diode Forward Voltage Drop VD VDB 0.7 Volts Bias Winding Diode Forward Voltage Drop KP 0.6 Ripple to Peak Current Ratio (0.4 < KRP < 1.0 : 1.0< KDP<6.0) ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type eer28 Core EER28 EER28 EER28 EER28_BOBBI Bobbin _BOBB N IN AE 1.18 1.18 1.18 LE 5.55 5.55 5.55 4600 4600 4600 AL 12.7 12.7 12.7 BW M Page 12 of 22 P/N: P/N: PC40EER28-Z BEER-28-1112CPH cm^2 cm nH/T^2 mm mm Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 L NS 30 W Adapter for Portable DVD 1 3 September 12, 2005 Number of Primary Layers Number of Secondary Turns DC INPUT VOLTAGE PARAMETERS VMIN VMAX 98 375 98 Volts 375 Volts Minimum DC Input Voltage Maximum DC Input Voltage CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS 0.52 0.38 1.04 0.63 0.54 0.52 0.38 1.04 0.63 0.54 Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current TRANSFORMER PRIMARY DESIGN PARAMETERS LP 597 Amps Amps Amps Amps NP NB ALG BM BP BAC 28 4 777 1902 2603 571 597 uHenri es 28 4 777 nH/T^2 1902 Gauss 2603 Gauss 571 Gauss ur LG BWE OD INS 1722 0.16 12.7 0.46 0.06 1722 0.16 12.7 0.46 0.06 DIA AWG 0.39 27 0.39 27 CM CMA 203 374 203 374 Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns Gapped Core Effective Inductance Maximum Flux Density at PO, VMIN (BM<3000) Peak Flux Density (BP<4200) AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core mm Gap Length (Lg > 0.1 mm) mm Effective Bobbin Width mm Maximum Primary Wire Diameter including insulation mm Estimated Total Insulation Thickness (= 2 * film thickness) mm Bare conductor diameter AWG Primary Wire Gauge (Rounded to next smaller standard AWG value) Cmils Bare conductor effective area in circular mils Cmils/ Primary Winding Current Capacity (200 < CMA < 500) Amp TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 9.62 9.62 Amps Peak Secondary Current ISRMS 4.79 4.79 Amps Secondary RMS Current 3.00 3.00 Amps Power Supply Output Current IO 3.73 3.73 Amps Output Capacitor RMS Ripple Current IRIPPLE CMS AWGS 958 20 958 Cmils 20 AWG DIAS ODS 0.81 4.23 0.81 mm 4.23 mm INSS 1.71 1.71 mm VOLTAGE STRESS PARAMETERS VDRAIN 598 598 Volts 51 76 51 Volts 76 Volts PIVS PIVB Page 13 of 22 Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency. The data were taken at the end of the output cable. The DC resistance of the cable is about 0.05 ohm. 9.1 Efficiency Full load efficiency 84% Efficiency (%) 82% 80% 78% 76% 74% 72% 70% 90 125 160 195 230 265 Input Voltage (VAC) Figure 4 – Efficiency vs input voltage 9.2 No-Load Input Power Integrations No load consumption 1 Input power (W) 0.8 0.6 0.4 0.2 0 90 125 160 195 230 265 Input Voltage (VAC) Figure 5 – No-load input vs input voltage, room temperature Page 14 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 9.3 30 W Adapter for Portable DVD September 12, 2005 Output regulation 9.3.1 Line regulation Line regulation 10 Output voltage (VDC) 8 6 4 2 0 90 125 160 195 230 265 Input Voltage (VAC) Figure 6 – Output voltage vs input voltage at 3.0 A load 9.3.2 Load regulation (taken at the end of the output cable) Output Voltage (VDC) Load regulation 10 9.9 9.8 9.7 9.6 9.5 9.4 9.3 9.2 9.1 9 115 VAC 0 0.5 1 230 VAC 1.5 2 2.5 3 Output Current (A) Figure 7 – Output voltage vs current 9.4 Thermal Performance Thermal was measured inside the sealed case, at worst case, which is at high line 265 VAC input, 3.0 A load. PSU was placed in still air, with ambient temperature of 42°C. Page 15 of 22 Item 265 VAC Ambient 42 °C TOP245Y 101 °C Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 9.5 Maximum output current This is the load current beyond which the PSU goes into auto-restart. Item Max. Io 115 VAC 3.76 A 230 VAC 3.83 A 10 Waveforms 10.1 Drain Voltage, Normal Operation Figure 8 – Drain voltage, 90 VAC input, 3.0 A load Figure 9 – Drain voltage 265 VAC, 3.0 A load 10.2 Output Voltage Start-up Profile Figure 10 – 115 VAC input, 3.0 A load Page 16 of 22 Figure 11 – 230 VAC, 3.0 A load Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 11 Output Ripple Measurements 11.1.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 12 and Figure 13. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 µF/50 V ceramic type and one (1) 1.0 µF/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below). Probe Ground Probe Tip Figure 12 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 13 – Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added) Page 17 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 11.1.2 Measurement Results Figure 14 – Output Ripple, 115 VAC, 3.0 A load Figure 15 – Output Ripple, 230 VAC, 3.0 A load Page 18 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 12 Loop performance Figure 16 – Gain/phase at 115 VAC input, 3.0 A load Figure 17 – Gain/Phase at 230 VAC input, 3.0 A load Page 19 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 13 Conducted EMI EMI was tested at 230 VAC input, 3.0 A resistive load. The worst case result occurs at 230VAC input with artificial hand. Figure 18 – Worst case conducted EMI, 230VAC, 3.0 A load Page 20 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 14 Revision History Date September 12, 2005 Page 21 of 22 Author YG Revision 1.0 Description & changes First Release Reviewed VC / AM Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-95 30 W Adapter for Portable DVD September 12, 2005 For the latest updates, visit our Web site: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. © Copyright 2004, Power Integrations. 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