Title Reference Design Report for a 35 W Power Supply Using TOP258PN Specification 90 VAC to 265 VAC Input 5 V, 2.2 A and 12 V, 2 A Output Application LCD Monitor Author Power Integrations Applications Department Document Number RDR-142 Date December 7, 2007 Revision 1.2 Summary and Features Low cost, low component count, high efficiency Delivers 35 W at 50 C ambient without requiring an external heat sink Meets output cross regulation requirements without linear regulators EcoSmart® – meets requirements for low no-load and standby power consumption 0.42 W output power for <1 W input No-load power consumption < 300 mW at 230 VAC >82% full load efficiency Integrated safety/reliability features: Accurate, auto-recovering, hysteretic thermal shutdown function maintains safe PCB temperatures under all conditions Auto-restart protects against output short circuits and open feedback loops Output OVP protection configurable for latching or self recovering Input UV prevents power up / power down output glitches Meets EN55022 and CISPR-22 Class B conducted EMI with > 10 dBµV margin 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-142 35 W, TOP258PN Dual Output Supply 07-Dec-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 TOPSwitch-HX Primary .......................................................................................7 4.3 Output Rectification .............................................................................................8 4.4 Output Feedback.................................................................................................9 4.5 PCB Layout .......................................................................................................10 5 Bill of Materials .........................................................................................................11 6 Transformer Specification.........................................................................................13 6.1 Electrical Diagram .............................................................................................13 6.2 Electrical Specifications.....................................................................................13 6.3 Materials............................................................................................................13 6.4 Transformer Build Diagram ...............................................................................14 6.5 Transformer Construction..................................................................................15 7 Design Spreadsheet .................................................................................................16 8 Performance Data ....................................................................................................20 8.1 Efficiency ...........................................................................................................20 8.1.1 Active Mode CEC Measurement Data........................................................20 8.2 No-load Input Power..........................................................................................22 8.3 Available Standby Output Power.......................................................................23 9 Regulation ................................................................................................................24 9.1.1 Load ...........................................................................................................24 9.1.2 Line ............................................................................................................25 9.1.3 Cross Regulation Matrix .............................................................................26 10 Thermal Performance ...........................................................................................27 11 Waveforms............................................................................................................28 11.1 Drain Voltage and Current, Normal Operation...................................................28 11.2 Output Voltage Start-up Profile..........................................................................28 11.3 Drain Voltage and Current Start-up Profile ........................................................30 11.4 Load Transient Response (75% to 100% Load Step) .......................................31 11.5 Output Over-voltage Protection .........................................................................32 11.6 Output Ripple Measurements............................................................................33 11.6.1 Ripple Measurement Technique ................................................................33 11.6.2 Measurement Results ................................................................................34 12 Line Surge.............................................................................................................35 13 Control Loop Measurements.................................................................................36 13.1 90 VAC Maximum Load.....................................................................................36 13.2 265 VAC Maximum Load...................................................................................36 14 Conducted EMI .....................................................................................................37 15 Revision History ....................................................................................................38 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output 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 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 1 Introduction This document is an engineering report describing a LCD Monitor power supply utilizing a TOP258PN. This power supply is intended as a general purpose evaluation platform for TOPSwitch-HX. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. Figure 1 – Populated Circuit Board Photograph (5”L x 2.84”W x 1.16”H). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 2 Power Supply Specification Description Symbol Min Typ Max Units Comment 265 64 0.3 VAC Hz W 3 Wire Input 5.25 100 2.2 14.4 V mV A V 500 mV 2 A Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 VIN fLINE 90 47 50/60 VOUT1 VRIPPLE1 IOUT1 VOUT2 4.75 5 Output Ripple Voltage 2 VRIPPLE2 Output Current 2 Total Output Power Continuous Output Power Efficiency Full Load IOUT2 0 9.6 0 35 POUT 1 CEC * 20% 20 MHz Bandwidth W 82 Standby Input Power Required Average Efficiency at 25, 50, 75 and 100 % of POUT 12 5% 20 MHz Bandwidth 81 o % Measured at POUT 25 C W 5 V @ 82 mA, 12 V @ 0 mA; Vin at 264 VAC % Per California Energy Commission (CEC) / Energy Star requirements Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge Differential Common Mode Surge Ring Wave Ambient Temperature TAMB 1 2 kV kV 1 kV 0 50 o C 1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: 12 100 kHz ring wave, 500 A Short Circuit Current, Differential and Common Mode Free Convection, Sea Level *Shown for information only as CEC requirement does not apply to internal power supplies Page 5 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 3 Schematic * Figure 2 – Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com *Optional for 2 wire input, floating output Page 6 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 4 Circuit Description A Flyback converter configuration built around TOP258PN is used in this power supply to obtain two output voltages. The 5 V output can supply a load current of 2.2 A, and the 12 V output can supply a load current of 2.0 A. This power supply can operate between 90 – 264 VAC. The 5 V output is the main regulated output. This output is regulated using a TL431 voltage reference. Some feedback is also derived from the 12 V output for improved cross regulation. 4.1 Input EMI Filtering The three wire AC supply is connected to the circuit using connector J1. Fuse F1 provides protection against circuit faults and effectively isolates the circuit from the AC supply source. Thermistor RT1 limits the inrush current drawn by the circuit at start up. Optional capacitors C1 and C2 are Y capacitors connected from the Line/Neutral to Earth to reduce common mode EMI. Capacitor C3 is the X capacitor and helps to reduce the differential mode EMI. Resistors R1 and R2 discharge C3 on AC removal, preventing potential user shock. Inductor L1 is a common-mode inductor and helps in filtering common-mode EMI from coupling back to the AC source. Diodes D1, D2, D3 and D4 form a bridge rectifier. The bridge rectifier rectifies the incoming AC supply to DC, which is filtered by capacitor C4. Diodes D1 and D3 are fast recovery type diodes. These diodes recover very quickly when the voltage across them reverses. This reduces excitation of stray line inductance in the AC input by reducing the subsequent high frequency turnoff snap and hence EMI. Only 2 of the 4 diodes in the bridge need to be fast recovery type, since 2 diodes conduct in each half cycle. 4.2 TOPSwitch-HX Primary Resistor R3 and R4 provide line voltage sensing and provide a current to U1, which is proportional to the DC voltage across capacitor C4. At approximately 95 V DC, the current through these resistors exceeds the line under-voltage threshold of 25 µA, which results in enabling of U1. The TOPSwitch-HX regulates the output using PWM-based voltage mode control. At high loads the controller operates at full switching frequency (66 kHz for P package devices). The duty cycle is controlled based on the control pin current to regulate the output voltage. The internal current limit provides cycle-by-cycle peak current limit protection. The TOPSwitch-HX controller has a second current limit comparator allowing monitoring the actual peak drain current (IP) relative to the programmed current limit ILIMITEXT. As soon Page 7 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 as the ratio IP/ILIMITEXT falls below 55%, the peak drain current is held constant. The output is then regulated by modulating the switching frequency (variable frequency PWM control). As the load decreases further, the switching frequency decreases linearly from full frequency down to 30 kHz. Once the switching frequency has reached 30 kHz the controller keeps this switching frequency constant and the peak current is reduced to regulate the output (fixed frequency, direct duty cycle PWM control). As the load is further reduced and the ratio IP/ILIMITEXT falls below 25%, the controller will enter a multi-cycle-modulation mode for excellent efficiency at light load or standby operation and low no-load input power consumption. Diode D5, together with R6, R7, C6 and Zener VR1, forms a clamp network that limits the drain voltage of U1 at the instant of turn-off. Zener VR1 provides a defined maximum clamp voltage and typically only conducts during fault conditions such as overload. This allows the RCD clamp (R6, C6 and D5) to be sized for normal operation, thereby maximizing efficiency at light load. Resistor R7 is required due to the choice of a fast recovery diode for D5. A fast versus ultra fast recovery diode allows some recovery of the clamp energy but requires R7 to limit reverse diode current and dampen high frequency ringing. The output of the bias winding is rectified by diode D6 and filtered by resistor R10 and capacitor C10. This rectified and filtered output is used by the optocoupler U2 to provide the control current to the control terminal of U1. Should the feedback circuit fail (open loop condition), the output of the power supply will exceed the regulation limits. This increased voltage at output will also result in an increased voltage at the output of the bias winding. Zener VR2 will break down and current will flow into the “M” pin of IC U1, thus initiating a hysteretic OVP shutdown with automatic restart attempts. Resistor R5 limits the current into the M pin; if latching OVP is desired, the value of R5 can be reduced to 20 . The output voltage of the power supply is maintained in regulation by the feedback circuit on the secondary side of the circuit. The feedback circuit controls the output voltage by changing the optocoupler current. Change in the optocoupler diode current results in a change of current into the control pin of IC U1. Variation of this current results in variation of duty cycle and hence the output voltage of the power supply. 4.3 Output Rectification Output rectification for the 5 V output is provided by diode D8. Low ESR capacitor C17 provides filtering. Inductor L3 and capacitor C18 form a second stage filter that significantly attenuates the switching ripple across C17 and ensures a low ripple output. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply Output rectification for the 12 V output is provided by diode D7. Low ESR capacitors C13 and C14 provide filtering. Inductor L2 and capacitor C15 form a second stage filter that significantly attenuates the switching ripple and ensures low ripple at the output. Snubber networks comprising R11, C12 and R12, and C16 damp high frequency ringing across diodes D7 and D8, which results from leakage inductance of the transformer windings and the secondary trace inductances. 4.4 Output Feedback Output voltage is controlled using the shunt regulator TL431 (U3). Diode D9, capacitor C20 and resistor R16 form the soft finish circuit. At start-up, capacitor C20 is discharged. As the output voltage starts rising, current flows into the optocoupler diode (U2A) via resistor R13 and diode D9. This provides feedback to the circuit on the primary side. The current in the optocoupler diode U2A gradually decreases as capacitor C20 charges and U3 becomes operational. This ensures that the output voltage increases gradually and settles to the final value without any overshoot. Resistor R16 provides a discharge path for C20 into the load at power down. Diode D9 isolates C20 from the feedback circuit after startup. Resistor R18, R20 and R21 form a voltage divider network that senses the output voltage from both the outputs for better cross-regulation. Resistor R19 and Zener VR3 improve cross regulation when only the 5 V output is loaded, which results in the 12 V output operating at the higher end of the specification. Resistors R13, R17 and capacitor C21 set the frequency response of the feedback circuit. Capacitor C19 and resistor R14 form the phase boost network that provides adequate phase margin to ensure stable operation over the entire operating voltage range. Resistor R15 provides the bias current required by the IC U3 and is placed in parallel with U2A to ensure that the bias current to the IC does not become a part of the feedback current. Resistor R13 sets the overall DC loop gain and limits the current through U2A during transient conditions. Page 9 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 4.5 07-Dec-07 PCB Layout Figure 3 – Printed Circuit Layout. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 5 Bill of Materials Item Qty 1 2 2 1 Ref Des C1 C2 C3 3 4 5 6 1 1 2 1 C4 C6 C7 C11 C8 7 1 8 2 9 2 10 2 C9 C10 C20 C12 C16 C13 C14 11 1 C15 12 1 C17 13 14 15 1 1 1 C18 C19 C21 16 17 2 2 D1 D3 D2 D4 18 19 20 21 22 23 24 2 1 1 1 1 1 2 D5 D6 D7 D8 D9 F1 J1 J2 J3 25 1 JP1 26 1 JP2 27 28 29 30 31 32 33 34 35 36 1 1 2 2 2 1 1 1 1 1 JP3 L1 L2 L3 R1 R2 R3 R4 R5 R6 R7 R8 R9 Page 11 of 40 Description Mfg Mfg Part Number 1 nF, Ceramic, Y1 220 nF, 275 VAC, Film, X2 100 uF, 400 V, Electrolytic, Low ESR, 630 mΩ (16 x 40) 3.9 nF, 1 kV, Disc Ceramic, Y5P 2.2 nF, Ceramic, Y1 100 nF, 50 V, Ceramic, Z5U 47 µF, 16 V, Electrolytic, Gen Purpose, (5 x 11.5) 10 µF, 50 V, Electrolytic, Gen Purpose, (5 x 11) Panasonic Panasonic Nippon Chemi-Con Panasonic Vishay Kemet ECK-ANA102MB ECQ-U2A224ML EKMX401ELL101ML40 S ECK-A3A392KBP 440LD22-R C317C104M5U5TA Panasonic ECA-1CHG470 Panasonic ECA-1HHG100 470 pF, 100 V, Ceramic, COG 680 µF, 25 V, Electrolytic, Very Low ESR, 23 mΩ, (10 x 20) 220 µF, 25 V, Electrolytic, Low ESR, 120 mΩ, (8 x 12) 2200 µF, 10 V, Electrolytic, Very Low ESR,21 mΩ, (12.5 x 20) 220 µF, 10 V, Electrolytic, Low ESR, 250 mΩ, (6.3 x 11.5) 1.0 µF, 50 V, Ceramic, X7R 220 nF, 50 V, Ceramic, X7R 600 V, 1 A, Fast Recovery Diode, 200 ns, DO-41 1000 V, 1 A, Rectifier, DO-41 800 V, 1 A, Fast Recovery Diode, 500 ns, DO-41 60 V, 5 A, Schottky, DO-201AD 30 V, 5 A, Schottky, DO-201AD 75 V, 300 mA, Fast Switching, DO-35 3.15 A, 250V,Fast, TR5 5 Position (1 x 5) header, 0.156 pitch 2 Position (1 x 2) header, 0.156 pitch Wire Jumper, Non insulated, 22 AWG, 0.4 in Wire Jumper, Non insulated, 22 AWG, 0.8 in Wire Jumper, Non insulated, 22 AWG, 0.3 in 6.8 mH, 0.8 A, Common Mode Choke 3.3 µH, 5.0 A 1 M, 5%, 1/4 W, Carbon Film 2.0 M, 5%, 1/4 W, Carbon Film 5.1 k, 5%, 1/4 W, Carbon Film 22 k, 5%, 2 W, Metal Oxide 20 R, 5%, 1/2 W, Carbon Film 6.8 R, 5%, 1/8 W, Carbon Film 100 R, 5%, 1/4 W, Carbon Film AVX Corp Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Epcos Epcos On Semiconductor Vishay 5NK471KOBAM Diodes Inc. Vishay Fairchild Vishay Wickman Molex Molex FR106 SB560 SB530 1N4148 37013150410 26-48-1055 26-48-1025 Alpha 298 Alpha 298 Alpha Panasonic Coilcraft Yageo Yageo Yageo Yageo Yageo Yageo Yageo 298 ELF15N008 RFB0807-3R3L CFR-25JB-1M0 CFR-25JB-2M0 CFR-25JB-5K1 RSF200JB-22K CFR-50JB-20R CFR-12JB-6R8 CFR-25JB-100R EKZE250ELL681MJ20S ELXZ250ELL221MH12D EKZE100ELL222MK20S ELXZ100ELL221MFB5D B37984M5105K000 B37987F5224K000 1N4937RLG 1N4007 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 37 1 38 39 40 41 2 1 1 1 42 43 44 45 46 47 2 1 1 1 1 1 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 RT1 48 1 T1 49 1 U1 50 1 U2 51 1 U3 52 53 54 1 1 1 VR1 VR2 VR3 07-Dec-07 4.7 R, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-4R7 33 R, 5%, 1/4 W, Carbon Film 330 R, 5%, 1/4 W, Carbon Film 22 R, 5%, 1/4 W, Carbon Film 1 k, 5%, 1/4 W, Carbon Film Yageo Yageo Yageo Yageo CFR-25JB-33R CFR-25JB-330R CFR-25JB-22R CFR-25JB-1K0 10 k, 5%, 1/4 W, Carbon Film 196 k, 1%, 1/4 W, Metal Film 10 R, 5%, 1/4 W, Carbon Film 12.4 k, 1%, 1/4 W, Metal Film 10 k, 1%, 1/4 W, Metal Film NTC Thermistor, 10 Ω, 1.7 A Core Bobbin: EER28, Horizontal, 12 pins (6/6), Complete Assembly (custom) Yageo Yageo Yageo Yageo Panasonic Thermometrics TDK Ying-Chin CFR-25JB-10K MFR-25FBF-196K CFR-25JB-10R MFR-25FBF-12K4 ERO-S2PHF1002 CL-120 PC40EER28-Z YC-2806-5 Ice Components Magtel Precision Inc. Santronics Power Integrations TP07074 32/07 TR.RDK-142 019-4967-00R SNX R1359 NEC On Semiconductor PS2501-1-H-A OnSemi Microsemi Vishay P6KE200ARLG 1N5250B BZX55B8V2 TOPSwitch-HX, TOP258PN, DIP-8B Optocoupler, 80 V, CTR 80-160%, 4-DIP 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92 200 V, 600 W, 5%, TVS, DO204AC (DO-15) 20 V, 5%, 500 mW, DO-35 8.2 V, 500 mW, 2%, DO-35 TOP258PN TL431CLPG Note – Parts listed above are RoHS compliant Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 6 Transformer Specification 6.1 Electrical Diagram Figure 4 – Transformer Electrical Diagram. 6.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 1 second, 60 Hz, from Pins 2,3,4,5,6 to Pins 7,9,11 Pins 2-4, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 2-4, all other windings open Pins 2-4, with Pins 7-9 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 1040 H, ±10% 1000 kHz (Min.) 20 H (Max.) 6.3 Materials Item Description [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] Core: EER28 gapped for ALG of 213 nH/T2. Bobbin: EER28, Horizontal 12 pins (6/6), YC-2806-5. Magnet Wire: #27 AWG, double coated. Magnet Wire: #26 AWG, double coated. Tape: 3M Polyester Film, 2.0 mils thick, 16.0 mm wide. Tape: 3M Polyester Film, 2.0 mils thick, 10.0 mm wide. Copper Foil, 2 mils thick, 142 mm long, 8.5 mm wide. To be wrapped over with tape item [6]. Tape: 3M Polyester Film, 2.0 mils thick, 13.5 mm wide. Bare Wire: #28 AWG. Tape: 3M Polyester Film, 2.0 mils thick, 8.0 mm wide. Varnish. Polyester Web Margin Tape 3.1 mm wide. Page 13 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 6.4 07-Dec-07 Transformer Build Diagram 2 3 11 7 9 11 5 6 3 4 margin tape ( 3.1 mm pre-molded margin bobbin) Bobbin: EER28 (Horizontal, 12pins, 6/6), YC-2806-5) Lp(2-4): 1.04mH +/- 5% Tape: 3M Polyester Film – 2mil thick 2 x #28AWG connected to pin 7 Copper Foil – 2mil thick 2 x #28AWG connected to pin 11 8.5mm 13.5mm 142mm Figure 5 – Transformer Build Diagram. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 40 07-Dec-07 6.5 RDR-142 35 W, TOP258PN Dual Output Supply Transformer Construction General Note Primary side of the bobbin orients to the left hand side. Place 3.1 mm margin tape on both sides for all windings except WD1 due to built-in 3.1 mm margin of bobbin [12]. Winding direction is clockwise. WD1 1/2 Primary Insulation WD2 Bias Insulation WD3 1st Secondary Insulation WD4 2nd Secondary Start on pin 4, wind 24 turns of item [3] from left to right with tight tension and bring the wire across the bobbin to terminate at pin 3. 2 layers of tape item [5]. Start on pin 6, wind 7 turns bifilar of item [4] from left to right, spread the winding evenly, and bring the wire across the bobbin to terminate on pin 5. 2 layers of tape item [5]. Start on pin 11, wind 3 turns of item [7] and terminate at pin 9. Insulation WD5 2/2 Primary Insulation Assembly Finish Page 15 of 40 1 layer of tape item [5]. Start on pin 7, wind 4 turns quadfilar of item [4] from right to left, spread the winding evenly across the bobbin, and bring the wire back to the right to terminate on pin 11. 2 layers of tape item [5]. Start on pin 3, wind 23 turns of item [3] from left to right with tight tension, place 1 layer tape item [6], then wind another 23 turns of item [3] from right to left, also with tight tension, and terminate at pin 2. 3 layers of tape item [5]. Grind the cores to get 1038 µH with ALG of 213 nH/T2. Secure the cores by wrapping around 2 halves of cores with item [10]. Dip varnish uniformly in item [11]. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 7 Design Spreadsheet ACDC_TOPSwitchHX_09 INPUT 0607; Rev.1.2; Copyright Power Integrations 2007 ENTER APPLICATION VARIABLES VACMIN 90 VACMAX 265 fL 50 VO 5.00 PO_AVG 35.00 PO_PEAK n 0.80 Z 0.50 VB 12 tC 3.00 CIN INFO OUTPU T 35.00 Info 100.0 100 ENTER TOPSWITCH-HX VARIABLES TOPSwitch-HX TOP258PN Chosen Device KI TOP258PN Power Out UNIT Volts Volts Hertz Volts Watts Watts %/100 Volts mSeco nds uFara ds Univer sal / Peak 35 W / 50 W 1.00 ILIMITMIN_EXT ILIMITMAX_EXT Frequency (F)=132kHz, (H)=66kHz 1.534 1.766 H Amps Amps fS 66000 Hertz fSmin fSmax High Line Operating Mode VOR VDS VD VDB KP 59400 72600 FF Hertz Hertz H 128.00 5.63 0.50 0.70 0.69 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 5.63 Volts Volts Volts Volts TOPSwitch_HX_090607: TOPSwitch-HX Continuous/Discontinuous Flyback Transformer Design Spreadsheet RD-142 Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage (main) Average Output Power Peak Output Power Efficiency Estimate Loss Allocation Factor Ensure proper operation at no load. Bridge Rectifier Conduction Time Estimate Input Filter Capacitor 115 Doubled/230V 48W External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Only half frequency option available for P, G and M package devices. For full frequency operation choose Y package. TOPSwitch-HX Switching Frequency: Choose between 132 kHz and 66 kHz TOPSwitch-HX Minimum Switching Frequency TOPSwitch-HX Maximum Switching Frequency Reflected Output Voltage TOPSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.3 < KRP < 1.0 : 1.0< KDP<6.0) Page 16 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply PROTECTION FEATURES LINE SENSING VUV_STARTUP 95.00 95 Volts VOV_SHUTDOWN 445 Volts RLS 4.0 Mohms OUTPUT OVERVOLTAGE VZ 22 Volts RZ 5.1 kohms OVERLOAD POWER LIMITING Overload Current Ratio at VMAX 1.2 Overload Current Ratio at VMIN ILIMIT_EXT_VMIN ILIMIT_EXT_VMAX RIL 1.25 1.23 1.14 8.29 RPL 29.27 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EER28 EER28 Core EER28 Bobbin EER28_BO BBIN AE 0.821 LE 6.4 AL 2870 BW M 3.00 16.7 L NS 3.00 3 A A kohms Mohms P/N: P/N: Zener Diode rated voltage for Output Overvoltage shutdown protection Output OVP resistor. For latching shutdown use 20 ohm resistor instead Enter the desired margin to current limit at VMAX. A value of 1.2 indicates that the current limit should be 20% higher than peak primary current at VMAX Margin to current limit at low line. External Current limit at VMIN External Current limit at VMAX Current limit/Power Limiting resistor. Power Limiting resistor Core Type PC40EER28-Z cm^2 cm nH/T^ 2 mm mm Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Minimum DC Input Voltage Maximum DC Input Voltage 3 DC INPUT VOLTAGE PARAMETERS VMIN VMAX 100 375 Volts Volts CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG 0.57 0.44 Amps IP 1.16 Amps IR 0.80 Amps IRMS 0.60 Amps Page 17 of 40 Note - For P/G package devices only one of either Line sensing or Overload power limiting protection features can be used. For all other packages both these functions can be simultaneously used. DC Bus Voltage at which the power supply will start-up DC Bus Voltage at which power supply will shut-down Use two standard, 2 MΩ, 5% resistors in series for line sense functionality. Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Maximum Duty Cycle (calculated at PO_PEAK) Average Primary Current (calculated at average output power) Peak Primary Current (calculated at Peak output power) Primary Ripple Current (calculated at average output power) Primary RMS Current (calculated at average output power) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP Tolerance NP NB ALG BM 1040 10 70 7 213 2101 uHenries BP 3524 Gauss BAC 725 Gauss ur LG BWE OD 1780 0.45 32.1 0.46 mm mm mm INS 0.06 mm DIA AWG 0.40 27 mm AWG CM CMA 203 338 Primary Current Density (J) 5.88 Cmils Cmils/A mp Amps/m m^2 nH/T^2 Gauss Primary Inductance Tolerance of 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) at ILIMITMAX and LP_MAX. Note: Recommended values for adapters and external power supplies <=3600 Gauss 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 (200 < CMA < 500) Primary Winding Current density (3.8 < J < 9.75) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 26.95 Amps Peak Secondary Current ISRMS 12.03 Amps Secondary RMS Current IO_PEAK 7.00 Amps Secondary Peak Output Current IO 7.00 Amps Average Power Supply Output Current IRIPPLE 9.79 Amps Output Capacitor RMS Ripple Current CMS 2407 Cmils Secondary Bare Conductor minimum circular mils AWGS 16 AWG Secondary Wire Gauge (Rounded up to next larger standard AWG value) DIAS 1.29 mm Secondary Minimum Bare Conductor Diameter ODS 3.57 mm Secondary Maximum Outside Diameter for Triple Insulated Wire INSS 1.14 mm Maximum Secondary Insulation Wall Thickness VOLTAGE STRESS PARAMETERS VDRAIN 625 Volts PIVS 21 Volts PIVB 49 Volts Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage Page 18 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 5.00 5 Volts Output Voltage IO1_AVG 2.20 2.2 Amps Average DC Output Current PO1_AVG 11.00 Watts Average Output Power VD1 0.5 Volts Output Diode Forward Voltage Drop NS1 3.00 Output Winding Number of Turns ISRMS1 3.782 Amps Output Winding RMS Current IRIPPLE1 3.08 Amps Output Capacitor RMS Ripple Current PIVS1 21 Volts Output Rectifier Maximum Peak Inverse Voltage CMS1 756 Cmils Output Winding Bare Conductor minimum circular mils AWGS1 21 AWG Wire Gauge (Rounded up to next larger standard AWG value) DIAS1 0.73 mm Minimum Bare Conductor Diameter ODS1 3.57 mm Maximum Outside Diameter for Triple Insulated Wire 2nd output VO2 IO2_AVG PO2_AVG VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 12.00 2.00 Volts Amps Watts Volts 24.00 0.7 6.93 3.438 2.80 49 Amps Amps Volts CMS2 688 Cmils AWGS2 21 AWG DIAS2 ODS2 0.73 1.54 mm mm 3rd output VO3 IO3_AVG PO3_AVG VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 0.00 0.7 0.38 0.000 0.00 2 CMS3 0 Cmils AWGS3 N/A AWG DIAS3 ODS3 N/A N/A mm mm Total Continuous Output Power 35 Watts Negative Output N/A Page 19 of 40 Volts Amps Watts Volts Amps Amps Volts Output Voltage Average DC Output Current Average Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Output Voltage Average DC Output Current Average Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Total Continuous Output Power If negative output exists enter Output number; eg: If VO2 is negative output, enter 2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 8 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 8.1 Efficiency 84.5% 84.0% Efficiency (%) 83.5% 83.0% 82.5% 115 VAC 230 VAC 82.0% 81.5% 81.0% 80.5% 80.0% 20.0% 40.0% 60.0% 80.0% 100.0% Load (A) Figure 6 – Efficiency vs. Input Voltage, Room Temperature, 60 Hz. 8.1.1 Active Mode CEC Measurement Data All single output adapters, including those provided with products, for sale in California after Jan 1st, 2008 must meet the California Energy Commission (CEC) requirement for minimum active mode efficiency and no load input power. Minimum active mode efficiency is defined as the average efficiency of 25, 50, 75 and 100% of rated output power with the limit based on the nameplate output power: Nameplate Output (PO) Minimum Efficiency in Active Mode of Operation <1W 1 W to 49 W > 49 W 0.09 0.49 PO ln (PO) + 0.5 [ln = natural log] 0.85 For adapters that are single input voltage only, then the measurement is made at the rated single nominal input voltage (115 VAC or 230 VAC); for universal input adapters the measurement is made at both nominal input voltages (115 VAC and 230 VAC). To meet the standard, the measured average efficiency (or efficiencies for universal input supplies) must be greater than or equal to the efficiency specified by the CEC/Energy Star standard. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply Percent of Full Load 25 50 75 100 Average CEC specified minimum average efficiency (%) Efficiency (%) 115 VAC 230 VAC 80.6 82.7 83.0 82.7 82.2 80.5 83.7 83.9 84.0 83.0 82.0* *Although the CEC standard does not apply to this design, the data is provided for reference. More states within the USA and other countries are adopting this standard, for the latest up to date information please visit the PI Green Room: http://www.powerint.com/greenroom/regulations.htm Page 21 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 8.2 07-Dec-07 No-load Input Power 0.260 Input Power (W) 0.240 0.220 0.200 0.180 0.160 0.140 85 105 125 145 165 185 205 225 245 265 AC Input (VAC) Figure 7 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 8.3 Available Standby Output Power The chart below shows the available output power vs line voltage for an input power of 1 W, 2 W and 3 W. This measurement was taken by loading the 5 V output. 1.800 1.600 Output Power (W) 1.400 1.200 1 W Input Power 2 W Input Power 3 W Input Power 1.000 0.800 0.600 0.400 0.200 85 105 125 145 165 185 205 225 245 265 Input Voltage (VAC) Figure 8 – Available Standby Output Power for Fixed Levels of Input Power. Page 23 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 9 Regulation 9.1.1 Load 13.0 12.0 Output Voltage (V) 11.0 10.0 5 V Output, 115 VAC 9.0 5 V Output, 230 VAC 8.0 12 V Output, 115 VAC 7.0 12 V Output, 230 VAC 6.0 5.0 4.0 0 5 10 15 20 25 30 35 Output Power (W) Figure 9 – Load Regulation, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 9.1.2 Line 13.00 Output Voltage (V) 12.00 11.00 10.00 9.00 5 V Output 12 V Output 8.00 7.00 6.00 5.00 4.00 85 135 185 235 AC Input (VAC) Figure 10 – Line Regulation, Room Temperature, Full Load. Page 25 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 9.1.3 Cross Regulation Matrix The table below shows the data for the outputs under various loading conditions at 90 and 265 VAC. The regulation on the 5 V output was within ±5% under all conditions. 90 VAC constant 50 mA load on 12 V IO (12 V) IO (5 V) VO (5 V) VO (12 V) 0.05 0.05 4.96 12.23 0.05 0.5 4.9 13.12 0.05 1 4.85 13.82 0.05 1.5 4.82 14.4 0.05 2.2 4.79 14.9 265 VAC constant 50 mA load on 12 V IO (12 V) IO (5 V) VO (5 V) VO (12 V) 0.05 0.05 4.95 12.27 0.05 0.5 4.89 13.2 0.05 1 4.85 13.95 0.05 1.5 4.8 14.64 0.05 2.2 4.78 14.98 90 VAC - 12 V held constant at full load IO (12 V) IO (5 V) VO (5 V) VO (12 V) 2 0.05 4.99 11.7 2 0.5 4.97 12 2 1 4.96 12.14 2 1.5 4.95 12.27 2 2.2 4.94 12.4 265 VAC - 12 V held constant at full load IO (12 V) IO (5 V) VO (5 V) VO (12 V) 2 0.05 4.99 11.66 2 0.5 4.97 11.97 2 1 4.96 12.1 2 1.5 4.95 12.22 2 2.2 4.94 12.33 90 VAC constant 50 mA load on 5 V IO (5 V) IO (12 V) VO (12 V) 0.05 0.05 12.26 0.05 0.5 11.91 0.05 1 11.79 0.05 1.5 11.73 0.05 2 11.68 VO (5 V) 4.95 4.97 4.98 4.98 4.98 265 VAC constant 50 mA load on 5 V IO (5 V) IO (12 V) VO (12 V) 0.05 0.05 12.27 0.05 0.5 11.91 0.05 1 11.76 0.05 1.5 11.69 0.05 2 11.63 VO (5 V) 4.95 4.99 4.99 4.99 4.99 VO (5 V) 4.78 4.91 4.94 4.94 4.94 265 VAC constant 2.2 A load on 5 V IO (5 V) IO (12 V) VO (12 V) 2.2 0.05 14.87 2.2 0.5 12.96 2.2 1 12.55 2.2 1.5 12.98 2.2 2 12.32 VO (5 V) 4.8 4.91 4.93 4.94 4.94 90 VAC constant 2.2 A load on 5 V IO (5 V) IO (12 V) VO (12 V) 2.2 0.05 14.96 2.2 0.5 12.91 2.2 1 12.54 2.2 1.5 12.42 2.2 2 12.36 Table 1 – Cross Regulation Data Under Various Loading Conditions. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 10 Thermal Performance Measurements were taken with no air flow across the power supply. Item Temperature ( C) 90 VAC 265 VAC Ambient 50 51 Output Capacitor (C17) 71 61 Transformer (T1) 87 87 Clamp Diode 96 91 TOPSwitch (U1) 108 91 89 88 Source pin Rectifier (D8) Table 2 – Thermal Performance, Full Load. 90 VAC, 35 W load, 21 ºC Ambient Figure 11 – Infrared Thermograph of Open Frame Operation, at Room Temperature. Page 27 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 11 Waveforms 11.1 Drain Voltage and Current, Normal Operation Figure 12 – 90 VAC, Full Load. Upper: VDRAIN, 100 V, 5 s / div. Lower: IDRAIN, 0.5 A / div. Figure 13 – 265 VAC, Full Load. Upper: VDRAIN, 200 V, 5 s / div. Lower: IDRAIN, 0.5 A / div. 11.2 Output Voltage Start-up Profile Figure 14 – 5 V Start-up Profile, Full load; 90 VAC; 1 V/div, 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 15 – 5 V Start-up Profile, Full load; 265 VAC; 1 V/div, 5 ms / div. Page 28 of 40 07-Dec-07 Figure 16 – 12 V Start-up Profile, Full load; 90 VAC; 2 V/div, 5 ms / div. Page 29 of 40 RDR-142 35 W, TOP258PN Dual Output Supply Figure 17 – 12 V Start-up Profile, Full load; 265 VAC; 2 V/div, 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 11.3 Drain Voltage and Current Start-up Profile Figure 18 – 90 VAC Input and Maximum Load. Upper: VDRAIN, 100 V, 2 mS / div. Lower: IDRAIN, 0.5 A / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 19 – 265 VAC Input and Maximum Load. Upper: VDRAIN, 200 V, 2 mS / div. Lower: IDRAIN, 0.5 A / div. Page 30 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 11.4 Load Transient Response (75% to 100% Load Step) In the figures shown below, signal averaging was used to better enable viewing of the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response. Figure 20 – 5 V Transient Response, 90 VAC, 75-100-75% Load Step. Output Voltage 20 mV/div. Output Current 1 A / div, 10 ms / div. Figure 21 – 5 V Transient Response, 265 VAC, 75-100-75% Load Step. Output Voltage 20 mV/div. Output Current 1 A / div, 10 ms / div. Note: 12 V Output maintained at full load. Note: 12 V Output maintained at full load. Page 31 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 Figure 22 – 12 V Output in Response to 5 V Transient, 90 VAC, 75-100-75% Load Step. Output Voltage 50 mV/div. Output Current 1 A / div, 10 ms / div. Figure 23 – 12 V Output in Response to 5 V Transient, 265 VAC, 75-100-75% Load Step. Output Voltage 50 mV/div. Output Current 1 A / div, 10 ms / div. Note: 5 V Output maintained at full load. (Waveshape is combination of line ripple and transient response - see Figure 26) Note: 5 V Output maintained at full load. 11.5 Output Over-voltage Protection The figures below show the performance of the output overvoltage protection circuit when the control loop was opened. Figure 24 – 5 V Output in Response to Open Loop R5 = 5.1 kΩ to Configure Hysteretic Shutdown. Output Voltage 2 V/div, 1 s / div. Figure 25 – 5 V Output in Response to Open Loop R5 = 20 Ω to Configure Latching Shutdown. Output Voltage 2 V/div, 1 s / div. Note: 12 V Output maintained at no load. Note: 12 V Output maintained at no load. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 11.6 Output Ripple Measurements 11.6.1 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 below. The 4987BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/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 23 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 24 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter. (Modified with wires for ripple measurement, and two parallel decoupling capacitors added) Page 33 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 11.6.2 Measurement Results Figure 26 – 5 V Ripple, 90 VAC, Full Load. 2 ms, 5 mV / div. Figure 27 – 5 V Ripple, 115 VAC, Full Load. 2 ms, 10 mV / div. Figure 28 – 12 V Ripple, 90 VAC, Full Load. 2 ms, 20 mV /div. Figure 29– 12 V Ripple, 115 VAC, Full Load. 2 ms, 20 mV /div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 12 Line Surge Differential input line 1.2/50 µs surge testing was completed on a single test unit to IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load and operation was verified following each surge event. Surge Level (V) +500 -500 +1000 -1000 +2000 -2000 Input Voltage (VAC) 230 230 230 230 230 230 Injection Location Injection Phase (°) Test Result (Pass/Fail) L to N L to N L to N L to N L,N to G L,N to G 90 270 90 270 90 270 Pass Pass Pass Pass Pass Pass Note: Unit passes under all test conditions. Use a Slow Blow fuse at the input (F1) to increase differential surge withstand to 2 kV. Page 35 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 13 Control Loop Measurements 13.1 90 VAC Maximum Load Figure 30 – Gain-Phase Plot, 90 VAC, Maximum Steady State Load Vertical Scale: Gain = 10 dB/div, Phase = 30 /div. Crossover Frequency = 2.0 kHz Phase Margin = 65 . 13.2 265 VAC Maximum Load Figure 31 – Gain-Phase Plot, 265 VAC, Maximum Steady State Load Vertical Scale: Gain = 10 dB/div, Phase = 30 °/div. Crossover Frequency = 350 Hz, Phase Margin = 90 . Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply 14 Conducted EMI Conducted EMI measurements were made with the output connected to the earth ground connection on the LISN. The result below represents the worst case results. Figure 32 – Conducted EMI, Neutral Conductor, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits. Page 37 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-07 15 Revision History Date 24-Sep-07 24-Sep-07 Author SGK KM Revision 1.0 1.1 07-Dec-07 SGK 1.2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Description & changes Initial Release Corrected Ice Components part number Updated transformer materials list Reviewed Page 38 of 40 07-Dec-07 RDR-142 35 W, TOP258PN Dual Output Supply Notes Page 39 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Dec-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, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2007 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] GERMANY Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3911 Fax: +49-89-5527-3920 e-mail: [email protected] JAPAN Kosei Dai-3 Bldg., 2-12-11, Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033 Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN 5F, No. 318, Nei Hu Rd., Sec. 1 Nei Hu Dist. Taipei, Taiwan 114, R.O.C. Phone: +886-2-2659-4570 Fax: +886-2-2659-4550 e-mail: [email protected] CHINA (SHANGHAI) Rm 807-808A, Pacheer Commercial Centre, 555 Nanjing Rd. 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