Title Reference Design Report for a 36 W Continuous, 72 W Peak Power Supply Using PKS606YN Specification 90 – 265 VAC Input, 12 V, 36 W Continuous (72 W Peak) Output Application Variable Speed Motor Drive Author Power Integrations Applications Department Document Number RDR-128 Date August 16, 2007 Revision 1.0 Summary and Features • • • • Replaces a two-stage linear power supply and chopper circuit with a simple single-stage design Eliminates the chopper circuits normally used to achieve variable-speed control of DC motors Motor speed is controllable by a small potentiometer or a 3.6 V to 10 V variable DC voltage Easily meets CISPR-22 / EN55022B limits with E-Shields and Frequency jittering feature. 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 RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 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 PeakSwitch Primary ............................................................................................7 4.3 Under-voltage Protection and Fast AC Reset circuit ...........................................7 4.4 Output Rectification and Filtering ........................................................................8 4.5 Output Feedback.................................................................................................8 5 PCB Layout ................................................................................................................9 6 Bill of Materials .........................................................................................................10 7 Transformer Specification.........................................................................................12 7.1 Electrical Diagram .............................................................................................12 7.2 Electrical Specifications.....................................................................................12 7.3 Materials............................................................................................................12 7.4 Transformer Build Diagram ...............................................................................13 7.5 Transformer Construction..................................................................................14 8 Transformer Spreadsheet.........................................................................................15 9 Performance Data ....................................................................................................17 9.1 Efficiency ...........................................................................................................17 9.2 No-load Input Power..........................................................................................19 9.3 Regulation .........................................................................................................19 9.3.1 Load ...........................................................................................................19 9.3.2 Line ............................................................................................................20 9.4 Adjustable Output Voltage Characteristics ........................................................20 9.4.1 Resistor Control .........................................................................................20 9.4.2 External Voltage Control ............................................................................21 9.5 Thermal Performance........................................................................................21 10 Waveforms............................................................................................................23 10.1 Drain Voltage and Current, Normal Operation...................................................23 10.2 Output Voltage and Current Start-up Profile......................................................24 10.3 Drain Voltage and Current Start-up Profile ........................................................24 10.4 Transient Response ..........................................................................................25 10.5 Output Voltage and DC Bus Voltage Ripple ......................................................25 10.6 Latching Shutdown Operation ...........................................................................26 10.7 Output Ripple Measurements............................................................................27 10.7.1 Ripple Measurement Technique ................................................................27 10.7.2 Measurement Results ................................................................................28 11 Conducted EMI .....................................................................................................29 12 Revision History ....................................................................................................30 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply Important Note: 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 isolation transformer to provide the AC input to the prototype board. Page 3 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 1 Introduction This document is an engineering report describing a motor drive power supply capable of delivering up to 36 W of continuous power and up to 72 W of peak power, utilizing a PKS606YN device. This power supply is intended as a demonstration platform for the PeakSwitch family of devices and their application in motor drives. The PeakSwitch family of devices is ideally suited to this role due to their ability to provide very high peak power for short periods of time, as is often encountered in motor drive applications. This document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit board layout and performance data. Figure 1 – Populated Circuit Board Photograph. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 2 Power Supply Specification Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Continuous Output Current 1 Peak Output Current 1 Total Output Power Continuous Output Power Peak Output Power Efficiency Full Load Symbol Min Typ Max Units Comment VIN fLINE 90 47 265 64 0.3 VAC Hz W 2 Wire – no P.E. 50/60 VOUT1 VRIPPLE1 IOUT1 IOUTPK 11.5 12.5 V mV A A POUT POUT_PEAK η 12 800 3 6.0 36 72 ± 5% 20 MHz bandwidth W W 80 % o Measured at POUT 25 C Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge Ambient Temperature Page 5 of 32 2 TAMB 0 kV 40 o C 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω Free convection, sea level Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 3 Schematic Figure 2 – Schematic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 4 Circuit Description The motor drive power supply shown in Figure 1 is a switch mode power supply design utilizing the flyback topology. 4.1 Input EMI Filtering Differential mode EMI filtering is provided by X-capacitor C3. Y-capacitors C1, C2, C10 and C12, together with the common-mode choke L1, provide common-mode EMI filtering. Additionally the transformer E-Shields™, together with the frequency jittering features, provide adequate EMI margins. 4.2 PeakSwitch Primary Fuse F1 protects the power supply from a catastrophic failure due to a short circuit fault. A high voltage DC bus is created from the AC line voltage by the full-wave rectifier formed by diodes D1-D4. Capacitor C4 smoothes and filters the rectified AC voltage. The PKS606YN (U1) integrates a high voltage MOSFET, along with startup and all necessary control circuitry. During the MOSFET’s on-time, current flows through the primary of transformer T1, storing energy in the transformer core. During the turn off event, the voltage across the primary winding reverses. A voltage equal to the sum of DC bus voltage and the reflected output voltage (VOR) appears across the DRAIN and SOURCE of the PeakSwitch, with an additional spike generated by the leakage inductance. A primary clamp circuit formed by D6, VR1, R3 and C5 limits this voltage and resets the leakage energy prior to the next switching cycle. Diode D7 rectifies the supply’s bias winding while capacitor C9 provides DC filtering. This bias supply is connected to the PeakSwitch’s BP pin via R7, which powers the device during normal operation. 4.3 Under-voltage Protection and Fast AC Reset circuit Under-voltage shutdown is implemented by a separate line rectifying diode, D5, which charges capacitor C7. Resistors R5 and R6 program the UV start-up voltage to approximately 104 VDC, which is the DC voltage across C7, at which a current equal to 25 µA flows into the EN/UV pin. This separate AC line sense network (formed by D5, C7) allows the PeakSwitch to identify the cause of a fault condition. If the input voltage is above the under-voltage threshold and the EN/UV pin has not been pulled low for 30 ms, a fault condition is assumed, and the PeakSwitch latches off. Once the supply is latched off, the AC line voltage must be removed to allow capacitor C7 to discharge and allow the current into the EN/UV pin to fall below 25 µA. Page 7 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 If the EN/UV pin has not been pulled low for 30 ms and the input voltage is below the under-voltage threshold, then the loss of regulation is assumed to be due to a low line condition, and the PeakSwitch will stop switching until the under-voltage threshold is exceeded again. 4.4 Output Rectification and Filtering Diode D9 rectifies the output voltage while capacitors C13 and C14 provide output filtering. The output capacitor current ripple rating is chosen to be sufficient for the maximum rated continuous/average load. Resistor R9 and capacitor C11 form a snubber network across diode D9, which reduces high frequency ringing that occurs during the diode turn off event. 4.5 Output Feedback The PeakSwitch family of devices uses a simple on/off control scheme. When a current greater than 240 µA is drawn from the EN/UV pin of U1, the subsequent switching cycle is disabled. The EN/UV pin is pulled low whenever phototransistor U2B of the optocoupler conducts enough current through R8, thus forward biasing D8 and turning on transistor Q1. Transistor Q1 then pulls current out of the EN/UV pin. Having the phototransistor’s collector connected to the bypass pin of the PeakSwitch gives a collector to emitter voltage (VCE) of approximately 5.8 V, which allows the phototransistor to source current more effectively while using the high gain, small signal transistor Q1 to draw the current from the EN/UV pin. Optocoupler U2’s high CTR (300% – 600%) ensures a fast control loop response. Diode D8 is placed close to Q1 and thus provides thermal compensation against Q1’s VBE drop. The output voltage is variable to allow for speed control of the DC motor. An adjustable shunt regulator, U3, has its cathode tied to its reference, making it behave as a voltage reference at approximately 1.24 V above the 1.1 V optocoupler’s LED (U2A) drop. When no external control voltage is applied at terminals J3, diode D10 remains reverse biased and potentiometer R12 controls the voltage of the divider network formed by itself, R13 and R10. Decreasing the value of R12 programs a new voltage set-point (and also a new speed), and the feedback loop now regulates to a lower output voltage. Setting potentiometer R12 to its minimum value regulates the output down to 2.35 V. An 11 V zener diode (VR2) is in place to ensure the output voltage does not regulate too far above 12 V, as may occur due to the large tolerances of most potentiometers (which may be as high as ±20%). The supply’s output voltage may also be controlled by an external DC control voltage applied at J3, with amplitude between 0 V and 10 V. Applying an external voltage above 3.5 V at J3 will forward bias diode D10 and will set the reference and cathode pin of the shunt regulator to the external control voltage. Applying a higher external control voltage allows more current to flow through the LED of the optocoupler and thus reduces the supply’s output voltage. If 10 V is applied at J3, the supply shuts down completely. Reducing the external control voltage after a shut down will start the power supply again. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 5 PCB Layout Figure 3 – Printed Circuit Layout. Page 9 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 6 Bill of Materials Item Qty Ref 1 2 C1 C2 2 1 C3 3 1 C4 4 1 C5 5 1 C6 6 7 1 1 C7 C8 8 1 C9 9 2 C10 C12 10 11 1 2 C11 C13 C14 12 1 C15 13 5 D1 D2 D3 D4 D5 14 1 D6 15 3 D7 D8 D10 16 1 D9 17 18 1 1 F1 HS PAD1 19 1 HS1 20 1 HS2 21 1 J1 22 2 J2 J3 23 2 JP1 JP5 24 1 JP2 25 2 JP3 JP4 Description Mfg 100 pF, Ceramic, Y1 Panasonic 680 nF, 275 VAC, Film,MPX Series, X2 180 uF, 400 V, Electrolytic, Low ESR, (18 x 40) 2.2 nF, 1 kV, Disc Ceramic Carli NIC Components Corp EPAG401ELL18 1MM40S NCD222K1KVY 5FF 4700pF, 1 kV, Thru Hole, Disc Ceramic 100 nF, 400 V, Film 220 nF, 50 V, Ceramic, Z5U, 0.2" L.S. 47 uF, 35 V, Electrolytic, Gen. Purpose, (5 x 11) 1 nF, Ceramic, Y1 Vishay/Sprague 562R5GAD47 Panasonic Kemet ECQ-E4104KF C322C224M5U5 CA ECA-1VHG470 Nippon Chemi-Con Panasonic Panasonic Mfg Part Number ECKANA101MB PX684K3ID6 ECKANA102MB 562R5GAT33 EKZE250ELL68 1MJ20S 330 pF, 1 kV, Disc Ceramic 680 uF, 25 V, Electrolytic, Very Low ESR, 23 mOhm, (10 x 20) Vishay Nippon Chemi-Con 1.0 uF, 50 V, Ceramic, X7R Epcos 1000 V, 1 A, Rectifier, DO-41 Vishay B37984M5105K 000 1N4007 800 V, 1 A, Fast Recovery Diode, 500 ns, DO-41 75 V, 300 mA, Fast Switching, DO-35 60 V, 10 A, Schottky, TO-220AC Diodes Inc. FR106 Vishay 1N4148 Vishay MBR1060 Wickman Bergpuist 3721315041 1009-58 Clark Precision Sheetmetal Clark Precision Sheetmetal Molex 60-00012-00 Molex 26-48-1021 Alpha 298 Alpha 298 Alpha 298 3.15 A, 250V, Slow, TR5 HEATSINK PAD, TO-220, Sil-Pad 1000 HEATSINK/Alum, TO220 1 hole, 2 mtg pins HEATSINK/Alum, TO220 1 hole, 2 mtg pins 3 Position (1 x 3) header, 0.156 pitch, Vertical 2 Position (1 x 2) header, 0.156 pitch, Vertical Wire Jumper, Non insulated, 22 AWG, 0.4 in Wire Jumper, Non insulated, 22 AWG, 0.3 in Wire Jumper, Non insulated, 22 AWG, 0.6 in Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 60-00020-00 26-48-1031 Page 10 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 26 1 L1 5.3 mH, 1 A, Common Mode Choke Nut, Hex, Kep 4-40, S ZN Cr3 plateing RoHS NPN, Small Signal BJT, 40 V, 0.2 A, TO-92 1.3 M, 5%, 1/4 W, Carbon Film Panasonic ELF15N010A 27 2 28 1 NUT1 NUT2 Q1 On Semiconductor 2N3904RLRAG 29 2 R1 R2 Yageo CFR-25JB-1M3 30 1 R3 62 R, 5%, 1/2 W, Carbon Film Yageo CFR-50JB-62R 31 1 R4 2.2 R, 5%, 1/8 W, Carbon Film Yageo CFR-12JB-2R2 32 1 R5 2.2 M, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-2M2 33 1 R6 2.4 M, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-2M4 34 1 R7 4.7 k, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-4K7 35 1 R8 20 R, 5%, 1/8 W, Carbon Film Yageo CFR-12JB-20R 36 1 R9 68 R, 5%, 1/2 W, Carbon Film Yageo CFR-50JB-68R 37 1 R10 1.21 k, 1%, 1/4 W, Metal Film Yageo 38 39 40 1 1 1 R11 R12 R13 2 k, 5%, 1/4 W, Carbon Film 5 k,Pot, 20%, 1/8 W, Vertical 30 R, 5%, 1/4 W, Carbon Film Yageo CTS Corp. Yageo MFR-25FBF1K21 CFR-25JB-2K0 296UD502B1N CFR-25JB-30R 41 1 R14 1 k, 1%, 1/4 W, Metal Film Yageo 42 1 RT1 Thermometrics 43 2 44 1 SCREW1 SCREW2 T1 NTC Thermistor, 0.34 Ohms, 1.7 A SCREW MACHINE PHIL 440X5/16 SS Transformer, 10 Pins, Vertical 45 1 U1 46 1 U2 47 1 U3 48 1 VR1 49 50 1 2 51 1 VR2 WASHER1 WASHER2 WASHER3 PeakSwitch, PKS606YN, TO-2207C Opto coupler, 35 V, CTR 300600%, 4-DIP 1.24V Shunt Reg IC 200 V, 600 W, 5%, TVS, DO204AC (DO-15) 11 V, 500 mW, 5%, DO-35 WASHER FLAT #4 SS Washer Nylon Shoulder #4 Building Fasteners MFR-25FBF1K00 CL-120 Yih-Hwa Enterprises Santronics Power Integrations PMSSS 440 0031 PH YW-360-02B SNX R1365 PKS606YN Sharp PC817XJ0000F National Semiconductor OnSemi LMV431ACZ P6KE200ARLG Diodes Inc Building Fasteners 1N5241B-T FWSS 004 Keystone 3049 Note – Parts listed above are all RoHS compliant Page 11 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 7 Transformer Specification 7.1 Electrical Diagram 2 st 9,10 1 – ½ Primary Secondary 19T X 2 - #31AWG (filled) 4T X4 - #23AWG_TIW (in 1.5 layers) 3 7,8 2nd – ½ Primary 19T X 2 - #31AWG (filled) 1 Shield 7T X 4 - #29AWG (filled) NC 4 Bias 5T X 2 - #29AWG (Spread) (scatterd) 5 Figure 4 – Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 1 second, 60 Hz, from Pins 1-5 to Pins 7 and 10 Pins 1-2, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 3-4, with Pins 8-9 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 148 µH, ± 12% 3 MHz (Min) 4 MHz (Max) 6 µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: PC40EE25-Z, TDK or equivalent gapped for AL of 104 nH/T2. Gap approx. 0.47 mm. Bobbin: EE25 Vertical 10 pin Magnet Wire: #31 AWG Magnet Wire: #29 AWG Triple Insulated Wire: #23 AWG Tape, 3M 1298 Polyester Film, 2.0 mil thick, 10.7 mm wide Varnish Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 32 16-Aug-07 7.4 RDR-128 36 W, 72 W Peak Variable Output Power Supply Transformer Build Diagram 1 3 1/2 Primary: 19T X 2 - #31AWG Shield: 7T X 4 - #29AWG Secondary: 4T X4 - #23AWG_TIW 5 Bias: 3 2 5T X 2 - #29AWG (Spread) (scatterd) 1/2 Primary: 1 (filled) (filled) 7,8 9,10 (in 1.5 layers) 4 19T X 2 - #31AWG (filled) Bobbin: EE25 Vertical Lp = 148 uH Figure 5 – Transformer Build Diagram. Page 13 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 7.5 16-Aug-07 Transformer Construction Bobbin Preparation 1st Half Primary Winding Insulation Bias Winding Insulation Secondary Winding Insulation Shield Winding 2nd Half Primary Winding Insulation Core Assembly Varnish Pin side of the bobbin is oriented to the left hand side. Winding direction is clockwise when viewed from the non-pin side. Start on pin 2, wind 19 bi-filar turns of item [3], Magnet Wire: #31 AWG, from left to right with tight tension and bring the wire back across the bobbin and terminate the winding on pin 3. Apply 1 layer of item [6], 3M 1298 Polyester Film tape, for insulation. Start on pin 5, wind 5 bi-filar turns of item [4], Magnet Wire: #29 AWG, from left to right, spreading the windings evenly across the bobbin. Bring the wire back across the bobbin and terminate the winding on pin 4. Apply 2 layers of item [6], 3M 1298 Polyester Film tape, for insulation. Start on pin 9 and 10 using 2 wires for each pin. Wind 4 quad-filar turns of item [5], #23 AWG Triple Insulated Wire, from right to left. Continue winding the second layer from right to left, spreading the turns evenly across the bobbin. Terminate the winding on pins 7 and 8 using two wires for each pin. Apply 2 layers of item [6], 3M 1298 Polyester Film tape, for insulation. Start on pin 1 and wind 7 quad-filar turns of item [4], Magnet Wire: #29 AWG from left to right with tight tension across the bobbin. Cut and finish the end. Start on pin 3, wind 19 bi-filar turns of item [3], Magnet Wire: #31 AWG, from left to right with tight tension and bring the wire back across the bobbin and terminate the winding on pin 1. Apply 3 layers of item [6], 3M 1298 Polyester Film tape, for insulation Assemble and secure core halves. Dip varnish assembled transformer with item [7], varnish. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 8 Transformer Spreadsheet ACDC_PeakSwitch_020107; INPUT Rev.1.13; Copyright Power Integrations 2007 ENTER APPLICATION VARIABLES VACMIN 90 VACMAX 265 fL 50 Nominal Output Voltage (VO) 12.00 Maximum Output Current (IO) 6.00 INFO Peak Power n 12.00 35.00 CIN Watts Watts 3.00 180.00 ILIMITMIN ILIMITMAX fSmin I^2fmin VDS VD VDB VCLO KP (STEADY STATE) KP (TRANSIENT) 35.00 72.00 0.60 ENTER PeakSwitch VARIABLES PeakSwitch PKS606Y Chosen Device VOR Volts 0.68 Z tC Estimate UNIT Volts Volts Hertz Volts Amps Minimum Output Voltage at Peak Load Continuous Power OUTPUT 180 PKS606Y 120 Amps Amps Hertz A^2k Hz Volts Volts Volts Volts Volts ENTER UVLO VARIABLES V_UV_TARGET 96 Volts V_UV_ACTUAL 100 Volts RUV_IDEAL 3.75 RUV_ACTUAL 3.90 Moh ms Moh ms BIAS WINDING VARIABLES VB NB PIVB 15.00 5 65 Volts Volts ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE25 EE25 Page 15 of 32 Input Capacitance PeakSwitch device 10 0.7 0.7 200 0.47 0.29 Core Bobbin Peak Output Power Efficiency Estimate at output terminals and at peak load. Enter 0.7 if no better data available Loss Allocation Factor (Z = Secondary side losses / Total losses) Bridge Rectifier Conduction Time Estimate PKS6 06Y 2.600 3.000 250000 1955 120.00 mSec onds uFar ads ACDC_PeakSwitch_020107_Rev1-13.xls; PeakSwitch Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Nominal Output Voltage (at continuous power) Power Supply Output Current (corresponding to peak power) Minimum Output Voltage at Peak Power (Assuming output droop during peak load) Continuous Output Power EE25 EE25_BOBBIN P/N: P/N: Minimum Current Limit Maximum Current Limit Minimum Device Switching Frequency I^2f (product of current limit squared and frequency is trimmed for tighter tolerance) Reflected Output Voltage (VOR <= 135 V Recommended) PeakSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Bias Winding Diode Forward Voltage Drop Nominal Clamp Voltage Ripple to Peak Current Ratio (KP < 6) Ripple to Peak Current Ratio under worst case at peak load (0.25 < KP < 6) Target DC under-voltage threshold, above which the power supply with start Typical DC start-up voltage based on standard value of RUV_ACTUAL Calculated value for UV Lockout resistor Closest standard value of resistor to RUV_IDEAL Bias winding Voltage Number of Bias Winding Turns Bias rectifier Maximum Peak Inverse Voltage User Selected Core Size(Verify acceptable thermal rise under continuous load conditions) PC40EE25-Z EE25_BOBBIN Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 AE LE AL BW 0.404 7.34 1420 10.20 cm^2 cm nH/T^2 mm M 0.00 mm Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Volts Volts Minimum DC Input Voltage Maximum DC Input Voltage Amps Duty Ratio at full load, minimum primary inductance and minimum input voltage Average Primary Current L NS 2.00 4 2 4 Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width DC INPUT VOLTAGE PARAMETERS VMIN VMAX 87 375 CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.61 IAVG 1.37 IP 2.60 Amps Minimum Peak Primary Current IR IRMS 1.21 1.82 Amps Amps Primary Ripple Current Primary RMS Current TRANSFORMER PRIMARY DESIGN PARAMETERS LP 148 LP_TOLERANCE NP ALG Target BM 12 38 104 3000 uHenrie s % BM 2910 Gauss BAC 677 Gauss ur LG BWE OD 2053 0.45 20.4 0.54 mm mm mm INS 0.07 mm DIA AWG 0.47 25 mm AWG CM CMA 323 177 Cmils Cmils/A mp nH/T^2 Gauss Typical Primary Inductance. +/- 12% to ensure a minimum primary inductance of 132 uH Primary inductance tolerance Primary Winding Number of Turns Gapped Core Effective Inductance Target Peak Flux Density at Maximum Current Limit Calculated Maximum Operating Flux Density, BM < 3000 is recommended AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils Primary Winding Current Capacity (100 < CMA < 500) TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP 24.57 ISRMS 13.82 IRIPPLE 12.45 CMS 2763 AWGS 15 Amps Amps Amps Cmils AWG Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) VOLTAGE STRESS PARAMETERS VDRAIN 665 Volts PIVS 52 Volts Maximum Drain Voltage Estimate (Assumes 20% zener clamp tolerance and an additional 10% temperature tolerance) Output Rectifier Maximum Peak Inverse Voltage Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 9 Performance Data The measurements were made at room temperature using open frame convectional cooling and a line frequency of 60 Hz. 9.1 Efficiency The efficiency data were obtained at an output power up to 36 W, with the output voltage set to 12 V and thus a load current of 3 A. Percent of Full Load 25 50 75 100 Efficiency (%) 115 VAC 80.2 81.2 81.3 78.2 230 VAC 80.2 79.8 80.7 80.7 Table 1 – Efficiency Data. Efficiency 82.0% 81.5% Efficiency (%) 81.0% 80.5% 80.0% 115 VAC 230 VAC 79.5% 79.0% 78.5% 78.0% 77.5% 77.0% 0.500 1.000 1.500 2.000 2.500 3.000 Load (A) Figure 6 – Efficiency vs. Load, Room Temperature, 60 Hz. Page 17 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 Efficiency vs. Output Voltage at 36 W 84.0% 82.0% Efficiency 80.0% 78.0% 115 VAC 230 VAC 76.0% 74.0% 72.0% 70.0% 5 6 7 8 9 10 11 Output Voltage (V) Figure 7 – Efficiency vs. Output Voltage with Full Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 32 16-Aug-07 9.2 RDR-128 36 W, 72 W Peak Variable Output Power Supply No-load Input Power No-load Input Power 0.4 0.35 Input Power (W) 0.3 0.25 0.2 0.15 0.1 0.05 0 85 105 125 145 165 185 205 225 245 265 285 Line Voltage (VAC) Figure 8 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. 9.3 Regulation 9.3.1 Load Load Regulation 12.5 12.45 Output Voltage (V) 12.4 12.35 12.3 115 VAC 230 VAC 12.25 12.2 12.15 12.1 12.05 12 0.000 0.500 1.000 1.500 2.000 2.500 3.000 Load (A) Figure 9 – Load Regulation, Room Temperature. Page 19 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 9.3.2 Line Line Regulation 12.5 12.45 Output Voltage (V) 12.4 12.35 12.3 12.25 12.2 12.15 12.1 12.05 12 85 135 185 235 285 Line Voltage (VAC) Figure 10 – Line Regulation, Room Temperature, Full Load. 9.4 Adjustable Output Voltage Characteristics 9.4.1 Resistor Control Resistor Control Characteristic 14 Output Voltage (V) 12 10 8 6 4 2 0 1 2 3 4 5 Potentiometer, R12 Resistance (kΩ) Figure 11 – Output Voltage vs. Potentiometer Resistance. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 9.4.2 External Voltage Control Control Voltage vs. Output Voltage 14.00 Output Voltage (V) 12.00 10.00 8.00 6.00 4.00 2.00 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 Control Voltage (V) Figure 12 – Output Voltage vs. External Control Voltage. 9.5 Thermal Performance Thermal testing of the unit was conducted in a thermal chamber under convectional cooling. The unit was placed horizontally. The volume of convectional cooling was limited by a cardboard box with dimensions 12” x 10” x 9” (Height x Width x Depth). This box was used to prevent forced air-cooling of the unit by the thermal chamber’s fan. The temperature of the PeakSwitch was measured by attaching a thermocouple to the device’s tab. The output diode’s temperature was monitored in an identical manner. The unit’s output voltage was approximately 12.5 V during testing with a load of 3 A. Item Page 21 of 32 Temperature (°C) 90 VAC 230 VAC Ambient 40 40 PeakSwitch, (U1) 106 100 Output Diode, (D9) 91 100 Transformer (T1) 93 94 Clamp (VR1) 115 113 Input Bridge (D1 – D4) 86 81 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 90 VAC, 36 W load, 21ºC Ambient Figure 13 – Infrared Thermograph of Open Frame Operation at Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 10 Waveforms 10.1 Drain Voltage and Current, Normal Operation Figure 14 – 90 VAC, Vout= 12 V, Io= 3 A Upper: VDRAIN, 100 V Lower: IDRAIN, 1.0 A / div, 5 µs / div. Figure 15 – 90 VAC, Vout= 2.3 V, Io= 3 A Upper: VDRAIN, 100 V Lower: IDRAIN, 1.0 A / div, 5 µs / div. Figure 16 – 230 VAC, Vout= 12 V, Io= 3 A Upper: VDRAIN, 100 V Lower: IDRAIN, 1.0 A / div, 5 µs / div. Figure 17 – 230 VAC, Vout= 2.3 V, Io= 3 A Upper: VDRAIN, 100 V Lower: IDRAIN, 1.0 A / div, 5 µs / div. Page 23 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 10.2 Output Voltage and Current Start-up Profile Figure 18 – Start-up Profile, 90 VAC Upper Trace: Output Voltage 5 V / div. Middle Trace: Output Current 1 A /div. Lower Trace: DC Bus Voltage 50 V /div. (Time base – 5 ms / div) Figure 19 – Start-up Profile, 230 VAC Upper Trace: Output Voltage 5 V / div. Middle Trace: Output Current 1 A /div. Lower Trace: DC Bus Voltage 100 V /div. (Time base – 5 ms / div) 10.3 Drain Voltage and Current Start-up Profile Figure 20 – 110 VAC Input Upper: Vout, 2 V / div. Middle: IDRAIN, 1 A / div. Lower: VDRAIN, 100 V (5 ms / div) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 21 – 265 VAC Input and Maximum Load. Upper: Vout, 2 V / div. Middle: IDRAIN, 1 A / div. Lower: VDRAIN, 100 V (5 ms / div) Page 24 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 10.4 Transient Response Figure 22 – 90 VAC Input Upper: Vout, 500 mV / div. (AC coupled) Lower: IDRAIN, 2 A / div. (10 ms / div) Figure 23 – 265 VAC Input and Maximum Load. Upper: Vout, 500 mV / div. (AC coupled) Lower: IDRAIN, 2 A / div. (10 ms / div) 10.5 Output Voltage and DC Bus Voltage Ripple For this measurement the supply’s full peak power was pulsed for approximately 50 ms and the DC bus voltage was measured in addition to the output voltage’s ripple. Figure 24 – 90 VAC Input, Vout=11 V Upper Trace: DC Bus Voltage 100 V / div. Middle Trace: Vout Ripple, 1 V / div. Lower Trace: Iout=7 A 50 ms / div. Page 25 of 32 Figure 25 – 230 VAC Input, Vout=11 V Upper Trace: DC Bus Voltage 100 V / div. Middle Trace: Vout Ripple, 1 V / div. Lower Trace: Iout=12 A 50 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 10.6 Latching Shutdown Operation The waveform shown below illustrates the power supply’s latching shutdown feature. This feature is invaluable in a motor application due to the short circuit condition that can occur if the motor were to become jammed. Figure 26 – Latching Shutdown Operation. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 10.7 Output Ripple Measurements 10.7.1 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 the figures below. The 4987BA 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 27 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 28 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter. (Modified with wires for ripple measurement and two parallel decoupling capacitors added) Page 27 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 10.7.2 Measurement Results Figure 29 – 90 VAC Input, Vout=12 V, Io = 3 A Upper Trace: Vout Ripple, 500 mV / div. Lower Trace: VDrain, 100 V /div. (5 µs / div) Figure 30 – 90 VAC Input, Vout=2.3 V, Io = 3 A Upper Trace: Vout Ripple, 500 mV / div. Lower Trace: VDrain, 100 V /div. (5 µs / div) Figure 31 – 230 VAC Input, Vout=12 V, Io = 3 A Upper Trace: Vout Ripple, 500 mV / div. Lower Trace: VDrain, 100 V /div. (5 µs / div) Figure 32 – 230 VAC Input, Vout=12 V, Io = 3 A Upper Trace: Vout Ripple, 500 mV / div. Lower Trace: VDrain, 100 V /div. (5 µs / div) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply 11 Conducted EMI The following worst case conducted EMI measurements were made with a load of 3 A with the output grounded. Figure 33 – Conducted EMI, Maximum Steady State Load, 90 VAC, 60 Hz, and EN55022 B Limits. Figure 34 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits. Page 29 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 12 Revision History Date 16-Aug-07 Author SK Revision 1.0 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Description & changes Initial Publication Reviewed Page 30 of 32 16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply Notes Page 31 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07 For the latest updates, visit our website: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY 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 transformer construction and circuits external to the products) 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 grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2006 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. 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