Design Example Report Title 42W, 4 Output Supply using TOP245Y Specification Input: 230 VAC Outputs: 5V/4A, 6.8V/1.8A, 12V/0.8A, -10V/0.1A Application Set Top Box w/Hard Drive Author Power Integrations Applications Department Document Number DER-36 Date April 27, 2004 Revision 1.0 Summary and Features • • • • • High Efficiency (81% min) Low Parts Count Low Output Ripple Meets Conducted CISPR22B EMI with Margin Small Transformer (EER35) 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-36 42W, 4 Output Set Top Box Supply April 27, 2004 Table Of Contents 1 2 3 4 Introduction................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 Circuit Description ...................................................................................................... 6 4.1 Input EMI Filtering ............................................................................................... 6 4.2 TOPSwitch Primary ............................................................................................. 6 4.3 Output Rectification ............................................................................................. 6 4.4 Output Feedback................................................................................................. 6 5 PCB Layout ................................................................................................................ 7 6 Bill Of Materials .......................................................................................................... 8 7 Transformer Specification......................................................................................... 10 7.1 Electrical Diagram ............................................................................................. 10 7.2 Electrical Specifications..................................................................................... 10 7.3 Materials............................................................................................................ 11 7.4 Transformer Build Diagram ............................................................................... 11 7.5 Transformer Construction.................................................................................. 12 8 Transformer Spreadsheets....................................................................................... 13 9 Performance Data .................................................................................................... 17 9.1 Thermal Performance........................................................................................ 17 10 Waveforms............................................................................................................ 18 10.1 12V Output Turn Off .......................................................................................... 18 10.2 5V Transient Response..................................................................................... 19 11 Conducted EMI ..................................................................................................... 20 12 Revision History.................................................................................................... 22 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. 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 2 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 1 Introduction This document is an engineering report describing a 230VAC input, 4 output supply power supply utilizing a TOP245Y. This power supply is intended for use in a set top box. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. Page 3 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 2 Power Supply Specification Description Symbol Min Typ VIN fLINE 180 47 50 Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 VOUT1 VRIPPLE1 IOUT1 VOUT2 Output Ripple Voltage 2 VRIPPLE2 4.75 1 6.12 5.00 2.5 6.80 Max Units Comment 265 2 Wire – no P.E. 0.3 VAC Hz W 5.25 50 4 7.48 V mV A V 50 mV ± 5% 20 MHz Bandwidth ± 10% 20 MHz Bandwidth Output Current 2 IOUT2 1.2 1.5 1.8 A Output Voltage 3 VOUT3 10.8 12.0 13.2 V ± 10% 50 mV 20 MHz Bandwidth Output Ripple Voltage 3 VRIPPLE3 Output Current 3 IOUT3 0.2 0.8 2.5 A Output Voltage 4 VOUT4 -9 -10 -11 V ± 10% 50 mV 20 MHz Bandwidth 0.10 A 41.8 52.7 W W % Output Ripple Voltage 4 Output Current 4 Total Output Power Continuous Output Power Peak Output Power Efficiency VRIPPLE4 IOUT4 POUT POUT_PEAK η 0.05 80 Measured at POUT (42 W), 25 oC Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge 4 kV Surge 3 kV Ambient Temperature Page 4 of 23 TAMB 0 60 o C 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 3 Schematic Figure 1 – Schematic. Page 5 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 4 Circuit Description 4.1 Input EMI Filtering Components L5, L8, L10, C4, and C10 provide EMI filtering, while L4, L5, L10, SG1, and RV1 provide line surge protection. 4.2 TOPSwitch Primary Components D2, R1-2, and C5 comprise an RCD clamp with damping to limit the primary leakage spike. Use of a normal recovery diode in this clamp circuit allows some leakage energy to be recycled. Capacitors C16 and C19 bypass the U2 control pin. Components C19 and R9 also provide frequency compensation for U2. Resistor R8 sets the U2 current limit to 90% of its nominal value. 4.3 Output Rectification Output rectification and filtering is provided by D4 and C8-9 for the 5V output, D1 and C7 for the 6.8V output, D3 and C2 for the 12V output, and D7 and C12 for the –10V output. Components L1, 3, L6, L7, L9, C3, C6, C13 and C15 are used for additional high frequency filtering. Ferrite bead L2 is used to center the 12V output closer to its nominal value. 4.4 Output Feedback Output feedback is provided from the 5V output. Resistors R7 and R11 program the output voltage. The output error signal is coupled back to the supply primary via R5 and U1. Capacitor C18 and 10 compensate U3, while C17 allows current through U1 during startup to prevent output overshoot. Resistor R4 discharges C17 when the supply is off. Page 6 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 5 PCB Layout Figure 2 – Printed Circuit Layout. Page 7 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 6 Bill Of Materials Item Qty Part Reference 1 2 C1 C5 2 4 C2 C7 C8 C9 Description Mfg Part Number Mfg Cap,Cer,2200pF, 1KV, 10% Cap,Al Elect,1500uF,35V,12.5mmX35mm,LXZ Series,NIPPON CHEMI-CON DD-222 Vishay LXZ35VB152MK35LL Nippon Chemi-Con 3 3 C3 C13 C15 Cap,Al Elect,100uF,25V,6.3mmX11.5mm,NHG Series,Panasonic ECA-1EHG101 4 5 1 C4 1 C6 Cap,Cer,2.2nF, Y2, 250VAC Cap,Al Elect,470uF,35V,10mmX20mm,LXZ Series,NIPPON CHEMI-CON 440LD22 Cera-Mite LXZ35VB471MJ20LL Nippon Chemi-Con 6 7 1 C10 1 C11 Cap,Metal Poly,0.1uF, 250/275VAC Cap,Al Elect,100uF,400V,30mmX25mm,TSED Series, Panasonic ECQ-U2A104ML ECO-S2GP101CA 8 1 C12 Cap,Al Elect,100uF,25V,6.3mmX11.5mm,LXZ Series,NIPPON CHEMI-CON LXZ25VB101MF11LL Nippon Chemi-Con 9 1 C14 Cap,Al Elect,1uF,50V,5mmX11.5mm,NHG Series,Panasonic ECA-1HHG010 Panasonic 10 11 2 C16 C18 1 C17 Cap,Cer, 0.10 uF, 50V, X7R, 10% Cap,Al Elect,10uF,50V,5mmX11.5mm, NHG Series,Panasonic ECU-S1H104KBB ECA-1HHG100 Panasonic Panasonic 12 1 C19 Cap,Al Elect,47uF,16V,5mmX11.5mm,NHG Series,Panasonic ECA-1CHG470 Panasonic 13 1 D1 Rectifier Schottky 5A 60V DO-201AD SB560 14 Rectifier GPP 600V 1.5A DO-204 1N5397 15 16 5 D2 D5 D6 D8 D10 1 D3 1 D4 General Semiconductor Rectron Diode,Ultrafast, 8A, 100V Diode Schottky 45V 20A TO-220AB MUR820 MBR2045CT 17 18 19 20 21 22 1 1 1 1 1 1 Diode Schottky,100V 1A DO-41 Diode SGL JUNC 100V 4.0NS DO-35 FUSE T-LAG 3.15A, 250V,Slo-Blo Geound Wire Assembly AC Input Receptacle CONN HEADER 10POS(1 X10) .156 VERT TIN SB1100 1N4148 23 1 J4 24 5 L1 L3 L6 L7 Inductor,3.3uH,2.66A L11 D7 D9 F1 J1 J2 J3 Page 8 of 23 Panasonic Panasonic Panasonic ON Semiconductor General Semiconductor Diodes, Inc. Bel Fuse HJC-028 CONN HEADER 4POS(1 X 4) .156 VERT TIN Singatron Molex Molex 822LY_3R3M Toko Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 25 2 L2 Bead,Ferrite, 3.25X3.5 mm,43 material 2643001501 Fair-Rite 26 27 28 29 30 31 32 33 34 35 36 37 38 39 3 1 1 1 1 1 1 1 1 2 1 1 1 1 Inductor,40uH,Toroid LINE FILTER,10mH,1.2A Bead, Ferrite, 6.7mm X 3.5mm, 43 material Res, 10.0, 1/2W, 5%, Carbon Film Res, 100K ,1W, 5%, Metal Film Res, 4.7, 1/2W, 5%, Carbon Film Res, 10K, 1/8W, 5%, Carbon Film Res, 150, 1/8W, 5%, Carbon Film Res, 330, 1/8W, 5%, Carbon Film Res,10.0K, 1/4W, 1%, M-FILM Res,7.50K, 1/4W, 1%, M-FILM Res, 6.8, 1/8W, 5%, Carbon Film Res, 4.7K, 1/8W, 5%, Carbon Film Thermistor,5 Ohms,3 A 2743004112 CFR-50JB-10R RSF200JB-100K CFR-50JB-4R7 CFR-12JB-10K CFR-12JB-150R CFR-12JB-330R MFR-25FBF-10K0 MFR-25FBF-7K50 CFR-12JB-6R8 CFR-12JB-4K7 SCK-053 40 1 RV1 VARISTOR 275V 75J 14MM RADIAL LA V275LA20A TDK Fair-rite Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo THINKING ELECTRONICS Littlefuse 41 42 1 SG1 1 T1 Gas Tube,470V,5kA,Axial XFMR,HORIZ,16 Pin,776uH,EER35 Core B88069X5740S102 Epcos 43 1 U1 IC,PC817A,PHOTOCOUPLER TRAN OUT CTR 80- ISP817A 160% 4-DIP ISOCOM 44 1 U2 IC,TOP245Y,INT. OFF-LINE SWITCHER,60W,TO220-7C TOP245Y Power Int. 45 1 U3 IC,TL431CLP, ADJ SHUNT REG TO-92 TL431CLP TI L4 L5 L10 L8 L9 R1 R2 R3 R4 R5 R6 R7 R11 R8 R9 R10 RT1 Page 9 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 7 Transformer Specification 7.1 Electrical Diagram 14 1 WDG #6 30T 26 AWG 2 WDG #3A 3T Cu Foil 0.005” X 0.50” 15 WDG #1 30T 26 AWG WDG #3B 1T Cu Foil 0.005” X 0.50” WDG #5 5T 2 X 26 AWG WDG #3C 3T Cu Foil 0.005” X 0.50” Primary 4 Bias 9,10 5V 8 11,12 6 13 WDG#2 7T 2 X 26 AWG WDG #4 5T 2 X 26 AWG -10V 16 5 Figure 3 –Transformer Electrical Diagram 7.2 Electrical Specifications Electrical strength 60 Hz 1 second, From Pins 1-6 to Pins 7-12 Primary Inductance Pins 1-4, All other windings open, 100 kHz Resonant Frequency Pins 1-4, All other windings open Primary leakage Pins 1-4, Pins 7-12 inductance shorted, 100 kHz Page 10 of 23 3000 Vac 791uH+/-10% 1.3 MHz (min) <15 uH Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 7.3 April 27, 2004 Materials Item [1] [2] [3] [4] [5} [6] [7] [8] [9] [10] 7.4 42W, 4 Output Set Top Box Supply Description Core: EER35, ungapped, Nippon Ceramic NC-2H material or equiv. Gap for AL of 220 nH/T2 Bobbin: EER35 Horizontal 12 pin, TDK BEER35-1116CPH or equivalent Magnet Wire: #26 AWG Solderable Double Coated Copper Foil, 0.50” X 0.005” thick Tinned Bus Wire, 24 AWG Tape: 3M Type 1298 Polyester Film or equiv. 1.03” wide Tape: 3M Type 1298 Polyester Film or equiv. 0.65” wide Tape: 3M Type 1298 Polyester Film or equiv. 0.55” wide Tape: 3M Type 44. Polyester web or equiv. 0.24” wide (min) Transformer Varnish Transformer Build Diagram 1 2 8 1 ½ Primary Shield Tape 16 13 14 Secondaries 15 8,9 11,12 5 6 2 4 Bias ½ Primary Figure 4 – Transformer Build Diagram. Page 11 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 7.5 42W, 4 Output Set Top Box Supply April 27, 2004 Transformer Construction WINDING INSTRUCTIONS: Margin Taping Apply a 0.24” margin at each side of bobbin using item [9]. Match combined height of primary and bias windings. ½ Primary Winding Start at pin 4. Wind 30 turns of item [3] in a single layer. Finish at pin Basic Insulation Apply one layer of tape [8] for basic insulation. Bifilar Bias Winding Start at pin 6. Wind 7 bifilar turns of item [3] uniformly in a single layer, across entire width of bobbin. Finish on pin 5. Reinforced Insulation Apply three layers of tape [6] for reinforced insulation. Margin Taping Apply a 0.24” margin at each side of bobbin using item [9]. Match combined height of secondary windings. Secondary Foil Winding Prepare a cuffed foil assembly using items [4], [5], [7], and [8]. Starting at pin 14, wind 3 turn of foil, finish at pin 15. Wind one turn of foil, finish at pins 9 and 10, Wind three remaining turns, finish at pins 11 and 12. 10 V Bifilar Winding Starting at pin 13, wind 5 bifilar turns of item [4] directly on top of the foil winding. Space turns evenly across bobbin. Finish at pin 16. Reinforced Insulation Apply three layers of tape [6] for reinforced insulation. Margin Taping Apply a 0.24” margin at each side of bobbin using item [9]. Match combined height of primary and shield windings. Shield Winding Starting at Pin 1, wind 5 bifilar turns of item [3]. Spread turns evenly across bobbin. Finish at pin 8. Basic Insulation Apply one layer of tape [9] for basic insulation. ½ Primary Winding Starting at pin 2, wind 30 turns of item [3] in a single layer. Finish at pin 1. Outer Insulation Apply 3 Layers of tape [6] for outer insulation Varnish Impregnate transformer using item [10] Page 12 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 8 Transformer Spreadsheets ACDC_TOPGX_Rev1.7_082203 INPUT Copyright Power Integrations Inc. 2003 INFO INFO OUTPUT OUTPUT UNIT TOP_GX_FX_082203.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet ENTER APPLICATION VARIABLES VACMIN VACMAX fL VO PO 190 265 50 5 53 Volts Volts Hertz Volts Watts n Z VB tC 0.8 0.5 12 3 CIN 100 Efficiency Estimate Loss Allocation Factor Volts Bias Voltage mSeconds Bridge Rectifier Conduction Time Estimate uFarads Input Filter Capacitor ENTER TOPSWITCH-GX VARIABLES TOP-GX Chosen Device KI TOP245 TOP245 TOP245 Power Out Power Out Universal 60W 0.8 ILIMITMIN 1.296 1.296 Amps ILIMITMAX 1.584 1.584 Amps 132000 132000 Hertz fSmin 124000 124000 Hertz fSmax 140000 140000 Hertz Frequency - (F)=132kHz, (H)=66kHz fS F 132000 VOR VDS 110 10 Volts Volts VD 0.5 Volts VDB 0.7 Volts KP 0.60 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EER35 Core EER35 EER35 EER35_BOBBIN EER35_BOBBIN Bobbin AE 1.07 P/N: P/N: 1.07 cm^2 LE AL 9.08 2770 9.08 cm 2770 nH/T^2 BW 26.1 26.1 mm M Page 13 of 23 6 mm Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power 115 Doubled/230V 85W 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 Full (F) frequency option 132kHz TOPSwitch-GX Switching Frequency: Choose between 132 kHz and 66 kHz TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX 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 (0.4 < KRP < 1.0 : 1.0< KDP<6.0) PC40EER35-Z BEER-35-1116CPH 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-36 42W, 4 Output Set Top Box Supply L NS April 27, 2004 2 3 Number of Primary Layers Number of Secondary Turns DC INPUT VOLTAGE PARAMETERS VMIN VMAX 251 375 251 Volts 375 Volts Minimum DC Input Voltage Maximum DC Input Voltage CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS 0.31 0.26 1.20 0.72 0.49 0.31 0.26 1.20 0.72 0.49 Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current TRANSFORMER PRIMARY DESIGN PARAMETERS LP NP 791 60 791 uHenries 60 Amps Amps Amps Amps Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Gauss Maximum Flux Density at PO, VMIN (BM<3000) Gauss Peak Flux Density (BP<4200) Gauss 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/Amp Primary Winding Current Capacity (200 < CMA < 500) 7 7 ALG 220 220 BM 1482 1482 BP BAC 1951 445 1951 445 ur 1871 1871 LG BWE OD 0.56 28.2 0.47 0.56 28.2 0.47 INS 0.06 0.06 DIA AWG 0.41 27 0.41 27 CM 203 203 CMA 418 418 TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP ISRMS IO IRIPPLE 24.07 14.38 10.60 9.72 24.07 14.38 10.60 9.72 Amps Amps Amps Amps Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current CMS 2876 2876 Cmils 15 15 AWG 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 NB AWGS DIAS 1.45 1.45 mm ODS 4.70 4.70 mm INSS 1.62 1.62 mm VOLTAGE STRESS PARAMETERS VDRAIN 626 626 Volts Page 14 of 23 Maximum Drain Voltage Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 PIVS 24 24 Volts PIVB 55 55 Volts TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 5.0 2.500 IO1 PO1 VD1 0.5 12.50 3.00 NS1 ISRMS1 IRIPPLE1 3.391 2.29 Volts Amps 12.50 Watts Volts 3.00 3.391 Amps 2.29 Amps PIVS1 24 24 Volts CMS1 678 678 Cmils 21 21 AWG AWGS1 DIAS1 0.73 0.73 mm ODS1 4.70 4.70 mm 2nd output VO2 IO2 PO2 VD2 6.8 1.500 10.20 0.5 3.98 NS2 2.035 1.37 ISRMS2 IRIPPLE2 Volts Amps 10.20 Watts Volts 3.98 2.035 Amps 1.37 Amps PIVS2 32 32 Volts CMS2 407 407 Cmils 24 24 AWG AWGS2 DIAS2 0.51 0.51 mm ODS2 3.54 3.54 mm 3rd output VO3 IO3 PO3 VD3 Page 15 of 23 12.0 2.500 30.00 0.7 Volts Amps 30.00 Watts Volts Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage Output Voltage Output DC Current 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 Output DC Current 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 Output DC Current Output Power Output Diode Forward Voltage Drop Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 NS3 ISRMS3 IRIPPLE3 42W, 4 Output Set Top Box Supply 6.93 3.391 2.29 April 27, 2004 6.93 3.391 Amps 2.29 Amps PIVS3 55 55 Volts CMS3 678 678 Cmils 21 21 AWG AWGS3 DIAS3 0.73 0.73 mm ODS3 2.04 2.04 mm Page 16 of 23 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency, unless otherwise specified. 9.1 Thermal Performance Thermal measurements were made with the power supply mounted in the chassis, using a slip-on heat sink on the TOPSwitch. A thermocouple was attached to the heat sink next to the TOPSwitch source tab using solder. Another thermocouple was soldered to a length of adhesive-backed copper tape, which was attached to the transformer. A thermocouple was taped in the center of the chassis, with the junction in free air. This thermocouple was used to measure the ambient air temperature inside the chassis. All holes in chassis were sealed with tape except ventilation holes in chassis and holes used for load and thermocouple wires. A solid cardboard sheet was used as the chassis top lid. The thermal chamber temperature outside the chassis was adjusted until the desired temperature was attained inside the chassis. Due to the limited size of the thermal chamber, the chassis was inserted diagonally into the chamber, with the power supply side tilted up. This may mean that the local ambient temperature of the supply was higher than that that measured by the thermocouple, which was located in the chassis center. The internal ambient temperature was allowed to rise with the unit running at the worst case power dissipation (e.g. 180VAC) until the unit shutdown (S/D) and the maximum ambient temperature was then recorded. The device was allowed to cool and restart, and the thermals measured using the nominal supply voltage at both normal room ambient and the elevated temperature at which shut down occurred at low line. Item Page 17 of 23 180 230 VAC VAC 230 VAC Ambient 58 59 23 TOPSwitch (U3) S/D 122 87 Transformer (T1) S/D 73 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 10 Waveforms 10.1 12V Output Turn Off The waveforms shown below were taken with output loads set to 5V/4A, 6.8V/1.5A, and 12V/0.5A, with a fixed 100 ohm resistor on the –10V output. The 5V and 12V outputs were monitored with an oscilloscope. The oscilloscope was triggered on the falling edge of the 5V output. The waveforms show the rise in the lightly loaded 12V output just before the heavily loaded +5V output goes out of regulation after removal of AC power. Use of a heavy foil on the transformer secondaries, along with a small ferrite bead in series with the 12V rectifier, keeps the 12V overshoot within 5%. The ferrite bead also helps to center the 12V output. Figure 5 - 180 VAC, 5V/4A, 12V/0.5A, 6.8V/1.5A, 10msec/div Upper: 12V, 2V / div Lower: 5V, 1V / div Page 18 of 23 Figure 6 - 230 VAC, 5V/4A, 12V/0.5A, 6.8V/1.5A, 10msec/div Upper: 12V, 2V / div Lower: 5V, 1V / div Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 Figure 7 - 180VAC, 5V/4A, 12V/0.5A, 6.8V/1.5A, 10msec/div. Upper: 12V Output, 2V / div Lower: 5V Output, 1V / div. 10.2 5V Transient Response Transient response measurements were taken for the 5V output using a 1A-2.5A-1A current step, with the 12V output loaded to 0.5A, and the 6.8v output at 1.5A. The cathode terminal of the TL431 error amplifier was loaded to determine its voltage excursion under these transient conditions. As shown below, the cathode excursion of the TL431 does not approach saturation, under these load conditions. Figure 11 - 230VAC Input, 5V Load Step of 1A-2.5A1A, 1msec/div. Upper: 5V Load, 1A/div. Middle: TL431 Drain Voltage, 50mV/div. Lower: 5V Output, 50mV/div Page 19 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 11 Conducted EMI Tests were performed in open air with resistive load. The supply was mounted inside the chassis. The secondary return was connected to the chassis at the end of the load cable. The primary ground lead (when used) was connected to the chassis using the fast-on terminal provided at the chassis rear panel. The chassis was hard wired to the LISN ground. The margin at the second harmonic will be 2-3dB better using the TDK choke instead of the Panasonic choke. Figure 30 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits, ground wire connected to chassis. Page 20 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 Figure 30 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits, ground wire left open. Page 21 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 12 Revision History Date April 27, 2004 Page 22 of 23 Author RH Revision 1.0 Description & changes First Release Reviewed VC Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-36 42W, 4 Output Set Top Box Supply April 27, 2004 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. WORLD HEADQUARTERS Power Integrations 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] CHINA (SHENZHEN) Power Integrations International Holdings, Inc. Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu, Shenzhen, Guangdong, 518031, China Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: [email protected] ITALY Power Integrations s.r.l. Via Vittorio Veneto 12, Bresso, Milano, 20091, Italy Phone: +39-028-928-6001 Fax: +39-028-928-6009 e-mail: [email protected] SINGAPORE (ASIA PACIFIC HEADQUARTERS) Power Integrations, Singapore 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: [email protected] AMERICAS Power Integrations, Inc. 4335 South Lee Street, Suite G, Buford, GA 30518, USA Phone: +1-678-714-6033 Fax: +1-678-714-6012 e-mail: [email protected] GERMANY Power Integrations, GmbH Rueckertstrasse 3, D-80336, Munich, Germany Phone: +49-895-527-3910 Fax: +49-895-527-3920 e-mail: [email protected] JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama, 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN Power Integrations International Holdings, Inc. 17F-3, No. 510, Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: [email protected] CHINA (SHANGHAI) Power Integrations International Holdings, Inc. Rm 807, Pacheer, Commercial Centre, 555 Nanjing West Road, Shanghai, 200041, China Phone: +86-21-6215-5548 Fax: +86-21-6215-2468 e-mail: [email protected] INDIA (TECHNICAL SUPPORT) Innovatech 261/A, Ground Floor 7th Main, 17th Cross, Sadashivanagar Bangalore, India, 560080 Phone: +91-80-5113-8020 Fax: +91-80-5113-8023 e-mail: [email protected] KOREA Power Integrations International Holdings, Inc. 8th Floor, DongSung Bldg. 17-8 Yoido-dong, Youngdeungpo-gu, Seoul, 150-874, Korea Phone: +82-2-782-2840 Fax: +82-2-782-4427 e-mail: [email protected] UK (EUROPE & AFRICA HEADQUARTERS) 1st Floor, St. James’s House East Street Farnham, Surrey GU9 7TJ United Kingdom Phone: +44-1252-730-140 Fax: +44-1252-727-689 e-mail: [email protected] APPLICATIONS HOTLINE World Wide +1-408-414-9660 APPLICATIONS FAX World Wide +1-408-414-9760 ER or EPR template – Rev 3.4 – Single sided Page 23 of 23 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com