Power DER-51 16w power supply using top243p Datasheet

Design Example Report
Title
16W Power Supply using TOP243P
Input: 195Vac - 265Vac
Specification Output: 1.8V/600mA, 3.3V/750mA,
5V/520mA, 12V/0.8A
Application
Set Top Box
Author
Power Integrations Applications Department
Date
April 20, 2005
Document
Number
DER-51
Revision
1.0
Summary and Features
•
•
•
Low cost flyback platform power supply
Direct generation of 1V8, 3V3, 5V and 12V rails from transformer requires no
linear post regulation.
>60ms hold up time
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
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DER-51
16W STB Power Supply
April 20, 2005
Table Of Contents
1
2
3
4
Introduction................................................................................................................. 4
Power Supply Specification ........................................................................................ 5
Schematic................................................................................................................... 6
Circuit Description ...................................................................................................... 7
4.1
Input EMI Filtering ............................................................................................... 7
4.2
TOPSwitch Primary ............................................................................................. 7
4.3
Transformer details ............................................................................................. 7
4.4
Output Feedback................................................................................................. 7
5 PCB Layout ................................................................................................................ 8
6 Bill Of Materials .......................................................................................................... 9
7 Transformer Specification......................................................................................... 10
7.1
Electrical Diagram ............................................................................................. 10
7.2
Electrical Specifications..................................................................................... 10
7.3
Materials............................................................................................................ 10
7.4
Transformer Build Diagram ............................................................................... 11
7.5
Transformer Construction.................................................................................. 11
8 Design Spreadsheet................................................................................................. 13
9 Performance Data .................................................................................................... 15
9.1
Efficiency........................................................................................................... 15
9.2
Regulation ......................................................................................................... 16
9.2.1
Line ............................................................................................................ 16
9.2.2
Cross Regulation........................................................................................ 16
10
Thermal Performance ........................................................................................... 18
11
Waveforms............................................................................................................ 19
11.1 Drain Voltage and Current, Steady State Full Power Operation........................ 19
11.2 Drain Voltage and Current Start-up Profile........................................................ 19
11.3 Output Voltage Start-up Profile ......................................................................... 20
11.4 Load Transient Response (75% to 100% Load Step) ....................................... 21
11.5 Hold-up Time..................................................................................................... 22
11.6 Output Ripple Measurements............................................................................ 24
11.6.1 Ripple Measurement Technique ................................................................ 24
11.6.2 Measurement Results ................................................................................ 25
12
Surge Test Results ............................................................................................... 27
12.1 Differential Mode Surge Tests........................................................................... 27
12.2 Common Mode Surge Tests ............................................................................. 27
13
Conducted EMI ..................................................................................................... 28
14
Revision History.................................................................................................... 29
Page 2 of 30
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DER-51
16W STB Power Supply
April 20, 2005
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 3 of 30
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DER-51
16W STB Power Supply
April 20, 2005
1 Introduction
This document is a prototype engineering report describing a 16W power supply utilizing
a TOP243P.
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
Page 4 of 30
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DER-51
16W STB Power Supply
April 20, 2005
2 Power Supply Specification
Description
Input
Voltage
Frequency
No-load Input Power (230 VAC)
Output
Output Voltage 1
Output Ripple Voltage 1
Output Current 1
Output Voltage 2
Output Ripple Voltage 2
Output Current 2
Output Voltage 3
Output Ripple Voltage 3
Output Current 3
Output Voltage 4
Output Ripple Voltage 4
Output Current 4
Output Voltage 5
Output Ripple Voltage 5
Output Current 5
Total Output Power
Continuous Output Power
Efficiency
Symbol
Min
Typ
Max
Units
Comment
VIN
fLINE
85
47
265
64
0.3
VAC
Hz
W
2 Wire – no P.E.
50/60
VOUT1
VRIPPLE1
IOUT1
VOUT2
VRIPPLE2
IOUT2
VOUT3
VRIPPLE3
IOUT3
VOUT4
VRIPPLE4
IOUT4
VOUT5
VRIPPLE5
IOUT5
POUT
η
1.8
18
0.6
0.3
3.3
33
0.75
0.4
5
50
0.52
0.2
12
120
0.8
0.01
-5
10
10
16W
77
V
mV
A
V
mV
A
V
mV
A
V
mV
A
V
mV
mA
W
%
± 5%
20 MHz bandwidth
± 5%
20 MHz bandwidth
± 5%
20 MHz bandwidth
± 5%
20 MHz bandwidth
± 5%
20 MHz bandwidth
Measured at POUT (16 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 5 of 30
TAMB
0
50
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
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DER-51
16W STB Power Supply
April 20, 2005
3 Schematic
Figure 2 – Schematic
Page 6 of 30
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DER-51
16W STB Power Supply
April 20, 2005
4 Circuit Description
This power supply is based on a flyback converter using TOP243P.
4.1
Input EMI Filtering
Input differential mode EMI filtering is provided by the two bulk capacitors (C1 and C2) in
combination with the leakage inductance of the common-mode choke, T1. Shield winding
techniques have been used in the transformer to reduce common-mode noise and this
has resulted in the power supply requiring only a small 5mH, 0.2A CM-Choke and 1nF Y1
capacitor.
4.2
TOPSwitch Primary
The TOP243P has been configured to give over-voltage and under-voltage shutdown
protection by using the M-pin functionality. A slow 1N4007GP diode has been used in
the primary side leakage clamp since it has a specified reverse recovery of about 2uS.
This allows some of the clamp energy to be recycled and increases overall efficiency. A
small 100R resistor is placed in series with this diode to limit the pull-out current to a safe
level.
The input bulk storage capacitors have been oversized to provide the required 60ms
hold-up time.
4.3
Transformer details
Full transformer construction details are given in section 7. Shield windings have been
used to minimize core voltage potential and to minimize primary to secondary commonmode current flow. In order to generate the 1V8, 3V3, 5V and 12V rails accurately, 3
turns are used for the 1V8, 2 extra for the 3V3, 3 extra for the 5V and 6 extra for the 12V
rail.
4.4
Output Feedback
Feedback is derived from the 3V3 and 5V rails with approximately 50/50 influence split. A
TL431 and opto-isolator is used to feedback to the primary.
Page 7 of 30
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DER-51
16W STB Power Supply
April 20, 2005
5 PCB Layout
Figure 3 – Printed Circuit Layout
Page 8 of 30
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DER-51
16W STB Power Supply
April 20, 2005
6 Bill Of Materials
Part Reference
Value
C1 C2
10uF, 400V
C3 C16
100nF, 50V
C4 C18
47uF, 10V
C5
1nF, 450V
C6
1uF, 50V
C7 C8 C9 C10
C11 C12 C13
C15
C17
D1 D2 D3 D4
D5
D6 D11 D12
D7 D8
D13
D14
F1
L2 L3 L4
R1 R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R13
RT1
RV1
T1
T2
U1
U2
U3
Description
100 nF, 50 V, Ceramic, X7R
1.0 uF, 450 V, Disc Ceramic
220 uF, 35 V, Electrolytic, Very Low ESR, 56
mOhm, (8 x 15)
100 uF, 16 V, Electrolytic, Low ESR, 250
mOhm, (6.3 x 11.5)
100uF, 16V
10 uF, 50 V, Electrolytic, Gen Purpose, (5 x
11.5)
10uF, 50V
1 nF, Ceramic, Y1
1nF, 250VAC
1000 V, 1 A, Rectifier, DO-41
1N4007
1000 V, 1 A, Rectifier, Glass Passivated, 2 us,
DO-41
1N4007G
75 V, 300 mA, Fast Switching, DO-35
1N4148
60 V, 1.1 A, Schottky, DO-41
SB120
UG2D
UG2B
1 A, 250V, Slow, TR5
1A, 250V
3.3 uH, 2.66 A
3.3uH
1 R, 5%, 1/4 W, Carbon Film
1M0
6.8 R, 5%, 1/4 W, Carbon Film
6R8
100 k, 5%, 1 W, Metal Oxide
100k
100 R, 5%, 1/4 W, Carbon Film
100R
150 R, 5%, 1/4 W, Carbon Film
150R
10 k, 5%, 1/4 W, Carbon Film
10k
3.3 k, 5%, 1/4 W, Carbon Film
3k3
10 k, 1%, 1/4 W, Metal Film
10k0
6.04 k, 1%, 1/4 W, Metal Film
6k04
20 k, 1%, 1/4 W, Metal Film
20k0
130 R, 5%, 1/4 W, Carbon Film
130
NTC Inrush resistor
10R
275 V, 45 J, 10 mm, RADIAL
275
680 uH, 0.25 A,
10mH, 0.1A
Custom EF25
EF25
TOPSwitch-GX, TOP242P, DIP-8B
TOP243P
PC817
PC817
2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO92
TL431CLP
220uF, 35V
Page 9 of 30
Quantity
2
2
2
1
1
Manufacturer
Mfg Part Number
Panasonic
ECU-S1H104KBB
Panasonic
ECQ-E2W105KC
4
United Chemi-Con
KZE35VB221MH15LL
3
United Chemi-Con
LXZ16VB101MF11LL
1
1
4
Panasonic
Vishay
Vishay
ECA-1HHG100
440LD10
1N4007
1
3
2
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Vishay
Vishay
International Rectifier
1N4007GP
1N4148
11DQ06
Wickman
Toko
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
3,721,315,041
822LY-3R3M
CFR-25JB-1M0
CFR-25JB-6R8
RSF200JB-100K
CFR-25JB-100R
CFR-25JB-150R
CFR-25JB-10K
CFR-25JB-3K3
MFR-25FBF-10K0
MFR-25FBF-6K04
MFR-25FBF-20K0
CFR-25JB-130R
Littlefuse
Tokin
V275LA10
SBC1-681-251
1
1
Power Integrations
Sharp
TOP242P
PC817X1
1
Texas Instruments
TL431CLP
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DER-51
16W STB Power Supply
April 20, 2005
7 Transformer Specification
7.1
Electrical Diagram
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 6 - 10
Pins 1-4, all other windings open, measured at
100 kHz, 0.4 VRMS
Pins 1-4, all other windings open
Pins 1-4, with Pins 5-10 shorted, measured at
100 kHz, 0.4 VRMS
3000 VAC
2357 µH, 0/+20%
600 kHz (Min.)
70 µH (Max.)
Materials
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Description
Core: EF25, 3F3 material or magnetic equivalent
Bobbin: 10 pin EF25 bobbin
Magnet Wire: 0.15MM Heavy Nyleze
Magnet Wire: 0.375MM Heavy Nyleze
Tape: 3M Type 1298 Polyester Film or Equivalent
Margin Tape 3mm wide
Varnish
Page 10 of 30
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DER-51
7.4
16W STB Power Supply
April 20, 2005
Transformer Build Diagram
8
5V Winding
9
8
1V8 and 3V3
Windings
6
9
10
12V Winding
7
5
2
1
Bias
4
Primary
1
Core Shield
Primary
Secondary
Figure 5 – Transformer Build Diagram
7.5
Transformer Construction
Preparation
Core Shield
Basic Insulation
Primary
Basic Insulation
Bias Winding
Basic Insulation
12V Winding
Page 11 of 30
Orient the bobbin with the primary on the left. Apply 3mm margin tape [6]
to each side of the bobbin.
Start temporarily on the right hand side of the bobbin. Wind 26 bifilar turns
of item [3] from right to left over a single full layer. Don’t terminate the left
hand side of the winding but fix it in place with tape. Bring the right hand
side of the winding across to the left hand side and terminate onto pin 1.
Use two layers of item [5] for basic insulation.
Start at Pin 4 on the left hand side of the bobbin. Wind 48 turns of item
[3] in approximately 1 layer from left to right. Continue with one further full
layer of 48 turns from right to left in a single layer. Finish with one further
full layer of 48 turns from left to right. Bring finish lead back across bobbin
window and terminate onto pin 1.
Use two layers of item [5] for basic insulation.
Start temporarily on the right hand side of the bobbin. Wind 18 turns of
item [4] from right to left in a single full layer. Finish on pin 2. Bring
temporary start of the winding across the bobbin and termiante on pin 5. .
Use two layers of item [5] for basic insulation.
Start at Pin 10 on the right hand side of the bobbin. Wind 9 birifilar turns
of item [4] from right to left in a single layer. Bring the end of the winding
across the bobbin and terminate onto pin 9.
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DER-51
Basic Insulation
1V8 and 3V3
windings
Basic Insulation
5V Winding
Basic Insulation
Final Assembly
Page 12 of 30
16W STB Power Supply
April 20, 2005
Use two layers of item [5] for basic insulation
Start on pin 6 on the right hand side of the bobbin. Wind 3 quadrafilar
turns of item [4] from right to left, spreading evenly over the bobbin width.
Finish on pin 7. Start on pin 8 on the right hand side of the bobbin. Wind 2
quadrafilar turns of item [4] from right to left, interposing the winding with
the 1V8 winding. Finish on pin 6.
Use two layers of item [5] for basic insulation
Start on pin 10 on the right hand side of the bobbin. Wind 3 quadrafilar
turns of item [4] from right to left. Terminate on pin 9.
Use two layers of item [5] for basic insulation
Assemble and secure core halves. Varnish impregnate.
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DER-51
16W STB Power Supply
April 20, 2005
8 Design Spreadsheet
Power Supply Input
Var
Value Output 1 Output 2 Output 3 Output 4 Units
Description
(main)
VACMIN
195
Volts
Min Input AC Voltage
VACMAX
265
Volts
Max Input AC Voltage
FL
50
Hertz
Line Frequency
TC
1.75
mSeconds Diode Conduction Time
Z
0.59
Loss Allocation Factor
N
85.0
%
Efficiency Estimate
Power Supply Outputs
Var
Value Output 1
Output 2 Output 3 Output 4 Units
Description
(main)
VOx
1.80
3.30
5.00
12.00
Volts
Output Voltage
IOx
0.60
0.75
0.52
0.80
Amps
Output Current
VB
12.0
Volts
Bias Voltage
IB
0.006
Amps
Bias Current
Device Variables
Output 4 Units Description
Var
Value
Output 1 Output 2 Output 3
(main)
Device
TOP243P
PI Device Name
PO
15.8
Watts Total Output Power
VDRAIN
605
Volts Maximum Drain Voltage
VDS
3.25
Volts Drain to Source Voltage
FS
132000
Hertz Switching Frequency
KRPKDP
0.60
Continuous/Discontinuous
Operating Ratio
KI
1.00
KI Factor
ILIMITEXT
0.70
Amps Device Current Limit External
Minimum
ILIMITMIN
0.70
Amps Current Limit Minimum
ILIMITMAX
0.80
Amps Current Limit Maximum
IP
0.37
Amps Peak Primary Current
IRMS
0.14
Amps Primary RMS Current
DMAX
0.28
Maximum Duty Cycle
Power Supply Components Selection
Var
Value
Output 1 Output 2 Output 3 Outp Units
Description
(main)
ut 4
CIN
32.0
uFarads Input Capacitance
VMIN
257.8
Volts
Minimum DC Input Voltage
VMAX
374.8
Volts
Maximum DC Input Voltage
VCLO
150
Volts
Clamp Zener Voltage
PZ
2.5
Watts
Primary Zener Clamp Loss
VDB
0.70
Volts
Bias Diode Forward Voltage Drop
PIVB
60
Volts
Bias Rectifier Max Peak Inverse
Voltage
RLS1
4.7
MOhms Line sense resistor
VUVON_MIN
207.19
Volts
Minimum undervoltage threshold
beyond which Power supply will startup
VUVON_MAX
253.71
Volts
Maximum undervoltage threshold
before which Power Supply will start-up
VOVOFF_MIN
979.43
Volts
Minimum overvoltage threshold after
which Power Supply will turn off after
an over voltage condition
VOVOFF_MAX 1118.99
Volts
Maximum overvoltage threshold before
the Power Supply will turn off after an
over voltage condition
Comment: Drain voltage close to
Page 13 of 30
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DER-51
16W STB Power Supply
April 20, 2005
BVDSS at maximum OV threshold
Tip: Verify BVDSS during line surge,
decrease VUVON_MAX or reduce
VOR.
Power Supply Output Parameters
Var
Value Output 1 Output 2
(main)
VDx
0.30
0.50
PIVSx
10
Output 4
Units
Description
0.50
0.70
Volts
26
60
Volts
0.97
0.59
0.28
1.49
0.91
0.43
Amps
Amps
Amps
Output Winding Diode Forward
Voltage Drop
Output Rectifier Maximum Peak
Inverse Voltage
Peak Secondary Current
Secondary RMS Current
Output Capacitor RMS Ripple Current
Output 2
Output 3
18
ISPx
1.12
1.40
ISRMSx
0.68
0.85
IRIPPLEx
0.32
0.41
Transformer Construction Parameters
Var
Value
Output 1
(main)
Core/Bobbin E25/13/7
(EF25)
Core Manuf. Generic
Bobbin Manuf Generic
LP
2357
NP
142.9
NB
18.1
AWG
35
CMA
228
VOR
BW
M
L
AE
ALG
Output 3
Output 4
Units
Description
Core Type
uHenries
AWG
Cmils/A
100.00
15.30
3.0
3.00
52.50
115
Volts
mm
mm
mm^2
nH/T^2
BM
1150
BP
2520
BAC
345
LG
0.53
LL
47.1
LSEC
20
Secondary Parameters
Var
Value Output 1
(main)
NSx
3.0
Rounded Down NSx
Output 2
Output 3
Output 4
Units Description
5.4
5
7.9
7
18.1
18
Rounded Down Vox
3.00
4.40
11.90
Rounded Up NSx
6
8
19
Rounded Up Vox
3.70
5.10
12.60
27 - 30
28 - 32
26 - 30
Secondary Number of Turns
Rounded to Integer Secondary
Number of Turns
Volts Auxiliary Output Voltage for
Rounded down to Integer
Secondary Number of Turns
Rounded to Next Integer Secondary
Number of Turns
Volts Auxiliary Output Voltage for
Rounded up to Next Integer
Secondary Number of Turns
AWG Secondary Wire Gauge Range
AWGSx Range
Page 14 of 30
27 - 31
Gauss
Gauss
Gauss
mm
uHenries
nHenries
Core Manufacturer
Bobbin Manufacturer
Primary Inductance
Primary Number of Turns
Bias Winding Number of Turns
Primary Wire Gauge
Primary Winding Current
Capacity
Reflected Output Voltage
Bobbin Winding Width
Safety Margin Width
Primary Number of Layers
Core Cross Sectional Area
Gapped Core Effective
Inductance
Maximum Flux Density
Peak Flux density
AC Flux Density for Core Loss
Gap Length
Primary Leakage Inductance
Secondary Trace Inductance
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DER-51
16W STB Power Supply
April 20, 2005
9 Performance Data
All measurements performed at room temperature, 50 Hz input frequency.
9.1
Efficiency
All rails were loaded to full specified power as defined in section 2. Figure 6 below shows
the conversion efficiency as a function of input line voltage.
90
Efficiency (%)
85
80
75
70
65
60
180
200
220
240
260
280
Input Voltage (Vrms)
Figure 6- Efficiency vs. Input Voltage
Page 15 of 30
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DER-51
9.2
16W STB Power Supply
April 20, 2005
Regulation
9.2.1 Line
Regulation (% of Nominal)
115
110
-5V Rail
105
1V8 Rail
100
3V3 Rail
5V Rail
95
12V Rail
90
85
180
200
220
240
260
280
Input Voltage (Vrms)
Figure 7 –Load Regulation.
9.2.2 Cross Regulation
The defined minimum and maximum loads for the power supply are given in Table 1
below.
Rail Voltage (V)
-5
1.8
3.3
5
12
Min Current (A)
0.01
0.3
0.4
0.2
0.01
Max Current (A)
0.01
0.6
0.75
0.52
0.8
Table 1 - Minimum and Maximum Loads
Since realistic load combinations are as yet unknown, cross-regulation results are based
on all possible combinations of minimum and maximum load. Table 2 gives the output
voltages for each load combination based on the min/max loads given above.
Page 16 of 30
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DER-51
16W STB Power Supply
Combination
1V8 - 3V3 - 5V - 12V
-5V
1V8
XXXX
XXXM
XXMX
XXMM
XMXX
XMXM
XMMX
XMMM
MXXX
MXXM
MXMX
MXMM
MMXX
MMXM
MMMX
MMMM
-3.92
-4.91
-4.28
-4.88
-4.10
-4.92
-4.85
-4.88
-4.00
-4.90
-4.61
-4.87
-4.33
-4.90
-4.91
-4.89
1.79
1.82
1.80
1.82
1.81
1.83
1.83
1.84
1.72
1.76
1.74
1.77
1.75
1.78
1.77
1.79
Minimum Voltage (V)
Maximum Voltage (V)
-4.92
-3.92
Minimum % of Nominal (%)
Maximum % of Nominal (%)
98.40
78.40
Rail Voltages
3V3
April 20, 2005
5V
12V
3.25
3.24
3.27
3.26
3.22
3.23
3.25
3.24
3.25
3.24
3.27
3.26
3.22
3.23
3.24
3.24
5.08
5.08
5.02
5.04
5.16
5.14
5.08
5.09
5.09
5.08
5.02
5.04
5.16
5.14
5.08
5.09
12.47
11.49
12.77
11.56
12.80
11.62
13.10
11.69
12.57
11.50
12.87
11.57
12.94
11.63
13.19
11.70
1.72
1.84
3.22
3.27
5.02
5.16
11.49
13.19
95.56
102.22
97.58
99.09
100.40
103.20
95.75
109.92
Table 2 - Cross Regulation Measurements at 230Vac input
Page 17 of 30
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10 Thermal Performance
The operating temperature of key power stage components was measured for full output
power as a function of input line voltage. The PCB was mounted horizontally in free air
with a recorded lab ambient temperature of 28°C. Figure 8 shows the temperature of the
TOP243P, the transformer core, the 12V rail output cap and the input 22uF, 400V bulk
capacitor.
Temperature (Deg C)
90
TOP243P
80
70
Transformer Core
60
50
22uF, 400V Bulk Cap
40
12V Rail 220uF, 35V
Output Cap
Ambient
30
20
10
0
180
200
220
240
260
280
Input Voltage (Vrms)
Figure 8 - Key Component Operating Temperature
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11 Waveforms
11.1 Drain Voltage and Current, Steady State Full Power Operation
Figure 9 - 195 VAC, Full Load.
Lower: IDRAIN, 0.2 A / div
Upper: VDRAIN, 200 V, 5 µs / div
Figure 10 - 265 VAC, Full Load
Lower: IDRAIN, 0.2 A / div
Upper: VDRAIN, 200 V / div
11.2 Drain Voltage and Current Start-up Profile
Figure 11 - 195 VAC Input and Maximum Load.
Lower: IDRAIN, 0.2 A / div.
Upper: VDRAIN, 200 V & 1 ms / div.
Page 19 of 30
Figure 12 - 265 VAC Input and Maximum Load.
Lower: IDRAIN, 0.2 A / div.
Upper: VDRAIN, 200 V & 1 ms / div.
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11.3 Output Voltage Start-up Profile
Figure 13 - 230 VAC Input and Maximum Load.
Upper: 1V8 Voltage, 0.5 V / div.
Lower: -5V Voltage, 2 V & 10 ms / div.
Figure 14 - 230 VAC Input and Maximum Load.
Upper: 1V8 Voltage, 0.5 V / div.
Lower: 3V3 Voltage, 1 V & 10 ms / div.
Figure 15 - 230 VAC Input and Maximum Load.
Upper: 1V8 Voltage, 0.5 V / div.
Lower: 5V Voltage, 2 V & 10 ms / div.
Figure 16 - 230 VAC Input and Maximum Load.
Upper: 1V8 Voltage, 0.5 V / div.
Lower: 12V Voltage, 5 V & 10 ms / div.
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11.4 Load Transient Response (75% to 100% Load Step)
In the figures shown below, signal averaging was used to better enable viewing 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 17 – Transient Response, 230 VAC, 0.4A to 0.75A Current Change
on 3V3 output.
Top: 3V3 Rail Current, 0.2 A/div.
Bottom: AC Coupled 3V3 Rail Output Voltage
50 mV, 5 ms / div.
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11.5 Hold-up Time
Hold-up time was measured at full power output with 230Vac input. Figure 18 and Figure
19 below show the hold-up is greater than 60ms in worst case.
Figure 18 - Hold-up measured from top of mains cycle. Upper trace is mains voltage at 200V/div and lower
trace is 3V3 rail output voltage at 1V/div. Timebase is 20ms/div.
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Figure 19- Hold-up measured from center of mains cycle. Upper trace is mains voltage at 200V/div and
lower trace is 3V3 rail output voltage at 1V/div. Timebase is 20ms/div.
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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 in Figure 20 and Figure 21.
The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe
tip. The capacitors include one (1) 0.1 µF/50 V ceramic type and one (1) 1.0 µF/50 V
aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so
proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 20 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 21 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe
ground for ripple measurement, and two parallel decoupling capacitors added)
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11.6.2 Measurement Results
Figure 22 - -5V Rail Ripple, 230 VAC, Full Load.
5 ms, 20 mV / div
Figure 23 – 1V8 Rail Ripple, 230 VAC, Full Load.
5 ms, 5 mV / div
Figure 24 – 3V3 Rail Ripple, 230 VAC, Full Load.
5 ms, 5 mV / div
Figure 25 – 5V Rail Ripple, 230 VAC, Full Load.
5 ms, 5 mV / div
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Figure 26 – 12V Rail Ripple, 195 VAC, Full Load.
5 ms, 50 mV / div
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12 Surge Test Results
Surge tests were performed according to EN61000-4-5 for both differential and commonmode surge.
12.1 Differential Mode Surge Tests
The surge equipment guarantees 10% accuracy so the programmed surge level was set
10% higher than the required levels 1kV, 2kV and 3kV to ensure that in worse case the
surge level was high enough. Surges were performed at phase angles of 0°, 90°, 180°,
270° and 359° with two strikes of both positive and negative surge.
For 1kV, 2kV and 3kV levels, the surge had no effect on the PSU and power was
provided continually throughout the duration of the surge. With 4kV surge, the radial fuse
(3.15A) was destroyed but the PSU continued to operate when the fuse had been
replaced.
12.2 Common Mode Surge Tests
Common mode surge voltage of 3.3kV was applied between Live and Earth with phase
angles of 0°, 90°, 180°, 270° and 359° with both positive and negative going pulses.
Figure 27 below summarizes the results.
Phase Angle
0
Pulse Polarity
Positive
Negative
90
180
270
359
Strike 1 Normal Operation
Normal Operation
Normal Operation Normal Operation
Normal Operation
Strike 2 Normal Operation
Normal Operation
Power dropout for
Normal Operation Power dropout for about 0.5 second
about 0.5 second
Strike 1 Normal Operation
Power dropout for
about 0.5 second
Normal Operation Normal Operation Power dropout for about 1 second
Strike 2 Normal Operation
Normal Operation
Normal Operation Normal Operation
Normal Operation
Figure 27 – Results of Common-Mode Surge Testing
In all cases above, any PSU dropout was followed by full automatic recovery of the power
supply.
Page 27 of 30
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13 Conducted EMI
The measurements presented below are pre-compliance and should only be used for
guidance. Results are presented both with and without the output grounded. Output
grounded is indicative of functional grounding through a SCART lead.
Figure 28 – 230VAC input. Full load output with output floating
Figure 29 – 230VAC input. Full load output with output grounded to protective Earth
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14 Revision History
Date
April 20, 2005
Page 29 of 30
Author
IM
Revision
1.0
Description & changes
Initial release
Reviewed
VC / JC / AM
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For the latest updates, visit our Web site: www.powerint.com
Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your
use of any information, device or circuit described herein nor does it convey any license under its patent rights or the
rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS
ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
PATENT INFORMATION
The products and applications illustrated herein (including circuits external to the products and transformer
construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign
patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at
www.powerint.com.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power
Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations.
© Copyright 2004, Power Integrations.
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