POWERINT DER-98

Design Example Report
Title
41W (53Wpk) Power Supply using
TOP246Y
Input: 85 – 265 VAC
Specification Output: 30V/80mA, 23V/0.5A, 12V/2A,
5V/2A, 3.3V/1.5A
Application
Digital Video Recorder
Author
Power Integrations Applications Department
Document
Number
DER-98
Date
September 12, 2005
Revision
1.0
Summary and Features
•
•
•
•
•
•
No linear regulators used
One transformer solution
Good cross regulation
No heat sinks used in secondary
Low cost OVP using TO-92 SCR crowbar
Low EMI with low-cost EMI filter
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
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DER-98
41W (53W pk) DVR
September 12, 2005
Table Of Contents
1
2
3
4
5
Introduction ................................................................................................................... 4
Photograph.................................................................................................................... 4
Power Supply Specification........................................................................................... 5
Schematic ..................................................................................................................... 6
Circuit Description ......................................................................................................... 7
5.1
Input EMI Filtering .................................................................................................. 7
5.2
TOPSwitch Primary................................................................................................ 7
5.3
Outputs................................................................................................................... 7
5.4
Output Feedback.................................................................................................... 7
5.5
Output OV Protection ............................................................................................. 7
6 PCB Layout ................................................................................................................... 8
7 Bill Of Materials ............................................................................................................. 9
8 Transformer Specification ........................................................................................... 11
8.1
Electrical Diagram ................................................................................................ 11
8.2
Electrical Specifications ....................................................................................... 11
8.3
Materials............................................................................................................... 12
8.4
Transformer Build Diagram .................................................................................. 12
8.4.1
WD#3 Copper Foil build diagram: ................................................................. 13
8.4.2
WDG#4 & #5 Copper Foil build diagram: ...................................................... 13
8.5
Transformer Construction..................................................................................... 14
8.6
Transformer Spreadsheets................................................................................... 15
9 Performance Data ....................................................................................................... 18
9.1
Line and Load Regulation .................................................................................... 18
9.2
Efficiency.............................................................................................................. 19
9.3
Overvoltage Protection......................................................................................... 19
10
Thermal Performance .............................................................................................. 20
11
Control Loop Measurements.................................................................................... 21
11.1 110 VAC Maximum Continuous Load .................................................................. 21
11.2 230 VAC Maximum Continuous Load .................................................................. 21
12
Waveforms............................................................................................................... 22
12.1 Drain Voltage and Current, Normal Operation ..................................................... 22
12.2 Output Voltage Start-up Profile ............................................................................ 22
12.3 Drain Voltage Start-up Profile............................................................................... 23
13
Output Ripple Measurements .................................................................................. 24
13.1.1 Ripple Measurement Technique ................................................................... 24
13.1.2 Measurement Results ................................................................................... 25
14
Conducted EMI ........................................................................................................ 28
14.1 230V High Line EMI ............................................................................................. 28
15
Revision History....................................................................................................... 29
Page 2 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
Important Notes:
Although this board is designed to satisfy safety isolation requirements, the engineering
prototype has not been agency approved. Therefore, all testing should be performed using
an isolated source to provide power to the prototype board.
Design Reports contain a power supply design specification, schematic, bill of materials,
and transformer documentation. Performance data and typical operation characteristics
are included. Typically only a single prototype has been built.
Page 3 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
1 Introduction
This document is an engineering prototype report describing a PSU design using
TOP246Y. The design adopts a one-transformer solution, meets EMI and peak power with
good margin. The use of a smaller transformer is made possible by TOPSwitch-GX’s high
switching frequency with good switching performance, and the low EMI with a low-cost filter
is made possible because of TOPSwitch-GX’s frequency jitter and E-ShieldTM transformer
winding techniques.
This document contains the power supply specifications, schematic, Bill of materials,
transformer documentation, printed circuit layout, and performance data.
2 Photograph
Figure 1 – Circuit Board Photograph
Page 4 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
3 Power Supply Specification
Description
Input
Voltage
Frequency
Symbol
Min
Typ
Max
Units
Comment
VIN
fLINE
90
47
265
64
VAC
Hz
2 Wires System
50/60
Output Voltage 1
Output Ripple Voltage 1
VOUT1
VRIPPLE1
3.135
3.3
3.465
V
mV
+/- 5%
20 MHz Bandwidth for all the
outputs
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 (FL)
Output Ripple Voltage 4
Output Current 4
Output Voltage 5
Output Ripple Voltage 5
Output Current 5
Total Output Power
Continuous Output Power
Peak Output Power
Efficiency
IOUT1
VOUT2
VRIPPLE2
4.75
IOUT2
VOUT3
VRIPPLE3
VOUT4
VRIPPLE4
11.4
5.25
21.85
12
12.6
V
mV
23
24.15
30
V
mV
+/- 5%
20 MHz Bandwidth for all the
outputs
31.5
V
mV
0.08
A
POUT
POUT_PEAK
41
53
W
W
72.8
+/- 5%
20 MHz Bandwidth for all the
outputs
A
IOUT5
η
+/- 5%
20 MHz Bandwidth for all the
outputs
A
0.5
28.5
V
mV
A
2
IOUT4
VOUT5
VRIPPLE5
5.0
A
2
IOUT3
Environmental
Conducted EMI
Safety
Ambient Temperature
1.5
%
+/- 5%
20 MHz Bandwidth for all the
outputs
Actual load measurement
Measured at 230VAC, POUT
(41W), 25 oC
Meets CISPR22B / EN55022B
Designed to meet IEC950, UL1950
Class II
TAMB
25
o
C
Free convection, sea level
The power supply is designed to meet 53 W output power for a short period – a few
minutes. The output power is only thermally limited by the heat sink attached to the
TOP246Y. In the currently sized heat sink (80 x 35 x 3 mm), the continuous output power is
41W.
Page 5 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
4 Schematic
Figure 2 – Schematic
Note: C33, C34, C16, R51, R52, R53, Q2 and VR10 are added to the PCB bottom side.
Page 6 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
5 Circuit Description
The schematic in Figure 2 shows an off-line flyback converter using the TOP246Y. The
circuit is designed for 85 VAC to 265 VAC.
5.1 Input EMI Filtering
X-capacitor C32, and common-mode choke L1 act as an input filter to reduce common
mode and differential mode EMI. The AC line voltage is rectified and filtered to generate a
high voltage DC bus via D1-4 and C1.
5.2 TOPSwitch Primary
Diode D5, C6, and R4, R45 and VR5 clamp leakage spikes generated when the MOSFET
when U1 switches off. D5 is a glass-passivated normal recovery rectifier. The slow,
controlled recovery time of D5 allows energy stored in C6 to be recycled back to the high
voltage bus, significantly increasing efficiency. A normal (non-glass-passivated) 1N4007
should not be substituted for the glass-passivated device. C5 bypasses the U1 control pin.
C4 has three functions. It provides the energy required by U1 during startup, sets the autorestart frequency during fault conditions, and also acts to roll off the gain of U1 as a
function of frequency. R8 adds a zero to the control loop to help stabilize the power supply
control loop. Diode D6 and capacitor C3 provide rectified and filtered bias power for U1 and
U2. Components R39, R48 and R9 provide a signal to the U1 X pin to reduce current limit
at high line to keep the maximum output power consistent with low line. R47 and R38
provide OV/UV protection.
5.3 Outputs
The T1 output is rectified and filtered by Diodes D8-D12 and filtered by inductor/capacitor
networks on most outputs. NOTE: Large capacitors were used for the 12 V output in order
to prevent possible voltage overshoots from the reverse current coming from the Hard Disk
Drive motor. Testing with the actual unit may show that these capacitors can be reduced
for cost reduction.
5.4 Output Feedback
Output feedback is used from a combination of the 5 V and the 3.3 V rails. Resistors R31,
R32 and R30 develop a feedback voltage, which is fed to the reference regulator U3. U3
drives optocoupler U2 through resistor R27 to provide feedback information to the U1
control pin. The optocoupler output also provides power to U1 during normal operating
conditions. Capacitor C7 applies drive to the optocoupler during supply startup to reduce
output voltage overshoot. Capacitor C21 and R29 provide frequency compensation for
error amplifier U3.
5.5 Output OV Protection
Q2 is positioned across the 30 V output winding; upon OV on the 5 V, detected by VR10,
Q2 will be triggered ON to short the 30 V winding. The PS will go into auto-restart mode
until the OV fault is removed.
Page 7 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
6 PCB Layout
Figure 3 – Printed Circuit Layout
Note: Q1, D7, R31, R33, R50, C15, VR6, VR7, VR8 and VR9 are not stuffed on the PCB. C33,
C34, C16, R51, R52, R53, Q2 and VR10 are added to the PCB and mounted on the bottom side of
the PCB
Page 8 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
7 Bill Of Materials
Item
Part Ref.
Description
Mfg Part Number
1
Qua.
1 150 uF
Value
C1
150 uF, 400 V, Electrolytic, Low ESR, 410 mOhm, (16 x
KMX400VB151M16X60L United Chemi-Con
60)
L
2
3 22 uF
C3 C8 C9
22 uF, 50 V, Electrolytic, Very Low ESR, 340 mOhm, (5 x KZE50VB22RME11LL
Mfg
United Chemi-Con
11)
3
2 100 uF
C4 C7
100 uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11)
KME10VB101M5X11LL
United Chemi-Con
4
2 100 nF
C5 C21
100 nF, 50 V, Ceramic, X7R
ECU-S1H104KBB
Panasonic
5
2 1 nF
C6 C34
1 nF, 1 kV, Disc Ceramic
NCD102K1KVY5F
NIC Components Corp
6
1 220 uF
C10
220 uF, 35 V, Electrolytic, Very Low ESR, 56 mOhm, (8 x KZE35VB221MH15LL
United Chemi-Con
15)
7
1 1000 uF
C11
1000 uF, 25 V, Electrolytic, Very Low ESR, 21 mOhm,
KZE25VB102MK20LL
United Chemi-Con
KZE10VB222MK20LL
United Chemi-Con
1200 uF, 10 V, Electrolytic, Very Low ESR, 23 mOhm, (10 KZE10VB122MJ20LL
United Chemi-Con
(12.5 x 20)
8
1 2200 uF
C12
2200 uF, 10 V, Electrolytic, Very Low ESR, 21 mOhm,
(12.5 x 20)
9
1 1200 uF
C13
x 20)
10
2 220 uF
C14 C24
220 uF, 10 V, Electrolytic, Low ESR, 250 mOhm, (6.3 x
LXZ10VB221MF11LL
United Chemi-Con
ECQ-V1H103JL3
Panasonic
11.5)
11
1 10 nF
C16
10 nF, 50 V, Film
12
2 2700 uF
C22 C25
2700 uF, 25 V, Electrolytic, Very Low ESR, 16 mOhm, (16 KZE25VB272ML25LL
United Chemi-Con
x 25)
13
1 33 uF
C23
33 uF, 35 V, Electrolytic, Very Low ESR, 300 mOhm, (5 x KZE35VB33RME11LL
United Chemi-Con
11)
14
1 2.2 nF
C31
2.2 nF, Ceramic, Y1
440LD22
15
1 330 nF
C32
Safety X capacitor, 270V
Any
16
1 100 pF
C33
100 pF, 1 kV, Disc Ceramic
NCD101K1KVY5F
NIC Components Corp
17
4 1N4007
D1 D2 D3 D4 1000 V, 1 A, Rectifier, DO-41
1N4007
Vishay
18
1 1N4007GP
D5
1N4007GP
Vishay
19
1 BAV20
D6
200 V, 200 mA, Fast Switching, 50 ns, DO-35
BAV20
Vishay
20
1 BYV26B
D8
400 V, 1 A, Ultrafast Recovery, 30 ns, SOD57
BYV26B
Philips
21
1 SB560
D9
60 V, 5 A, Schottky, DO-201AD
SB560
Vishay
22
1 SB540
D10
40 V, 5 A, Schottky, DO-201AD
SB540
Vishay
23
1 UF4004
D11
400 V, 1 A, Ultrafast Recovery, 50 ns, DO-41
UF4004
Vishay
24
1 SB5100
D12
100 V, 5 A, Schottky, DO-201AD1
SB5100
Fairchild
25
2 1N4001
D13 D15
50 V, 1 A, Rectifier, DO-41
1N4001
Vishay
26
1 1N5817
D14
20 V, 1 A, Schottky, DO-41
1N5817
Vishay
27
1 2A
F1
2 A,250V, Slow, TR5
3,721,200,041
Wickman
28
1 1.560H x
HS1
Heatsink, Custom, Vestel, L Shaped
1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41
Vishay
0.080W x
2.675L
29
1 CON3
J9
AC Input Receptacle and Accessory Plug, PCBM
161-R301SN13
Kobiconn
30
1 CON8
J10
8 Position (1 x 8) header, 0.1 pitch, Vertical
22-28-4080
Molex
31
1 CON4
J11
4 Position (1 x 4) header, 0.1 pitch, Vertical
22-28-4049
Molex
32
1 6.2 mH
L1
6.2 mH, 1 A, Common Mode Choke
Any
Any
33
5 3.3 uH
L2 L3 L4 L5
3.3 uH, 2.66 A
822LY-3R3M
Toko
34
4 Mounting
M1 M2 M3 M4 PCB Terminal Hole
N/A
N/A
Q2
N/A
N/A
L6
Holes
35
1 MCR2206
Page 9 of 30
400V, 1.5A SCR
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DER-98
41W (53W pk) DVR
September 12, 2005
36
1 47 k
R4
47 k, 5%, 1 W, Metal Oxide
RSF100JB-47K
Yageo
37
1 240
R5
240 R, 5%, 1/8 W, Carbon Film
CFR-12JB-240R
Yageo
38
1 10
R6
10 R, 5%, 1/4 W, Carbon Film
CFR-25JB-10R
Yageo
39
2 6.8
R8 R10
6.8 R, 5%, 1/4 W, Carbon Film
CFR-25JB-6R8
Yageo
40
1 6.81 k
R9
6.81 k, 1%, 1/4 W, Metal Film
MFR-25FBF-6K81
Yageo
41
2 68
R27 R52
68 R, 5%, 1/4 W, Carbon Film
CFR-25JB-68R
Yageo
42
1 1k
R28
1 k, 5%, 1/4 W, Carbon Film
CFR-25JB-1K0
Yageo
43
1 20 k
R29
20 k, 5%, 1/8 W, Carbon Film
CFR-12JB-20K
Yageo
44
1 10 k
R30
10 k, 1%, 1/4 W, Metal Film
MFR-25FBF-10K0
Yageo
45
1 DNP
R31
46
1 30.9 k
R32
30.9 k, 1%, 1/4 W, Metal Film
MFR-25FBF-30K9
Yageo
47
2 1M
R38 R47
1 M, 5%, 1/4 W, Carbon Film
CFR-25JB-1M0
Yageo
48
2 8.2 M
R39 R48
8.2 M, 5%, 1/4 W, Carbon Film
CFR-25JB-8M2
Yageo
49
1 30
R45
30 R, 5%, 1/2 W, Carbon Film
CFR-50JB-30R
Yageo
50
2 560 k
R46 R49
560 k, 5%, 1/4 W, Carbon Film
CFR-25JB-560K
Yageo
51
1 2k
R51
2 k, 1%, 1/4 W, Metal Film
MFR-25FBF-2K00
Yageo
52
1 100
R53
100 R, 5%, 1/4 W, Carbon Film
CFR-25JB-100R
Yageo
53
1 5
RT1
NTC Thermistor, 5 Ohms, 4.7 A
CL150
Thermometrics
54
1 320 Vac
RV1
320 V, 26 J, 7 mm, RADIAL
V320LA7
Littlefuse
55
1 EER28L
T1
Bobbin, EER28L, Horizonal, 12 pins
YW-195-00B
Yih-Hwa Enterprises
56
1 TOP246Y
U1
TOPSwitch-GX, TOP246Y, TO220-7C
TOP246Y
Power Integrations
57
1 PC817A
U2
Opto coupler, 35 V, CTR 80-160%, 4-DIP
ISP817A, PC817X1
Isocom, Sharp
58
1 LMV431_A
U3
1.24V Shunt Reg IC
LMV431ACZ
National
59
1 1N5250B
VR4
20 V, 5%, 500 mW, DO-35
1N5250B
Microsemi
60
1 P6KE200A
VR5
200 V, 5 W, 5%, DO204AC (DO-15)
P6KE200A
Vishay
61
1 1N5234B
VR10
6.2 V, 5%, 500 mW, DO-35
1N5234B
Microsemi
Semiconductor
NOTE: Large capacitors were used for the 12 V output in order to prevent possible voltage
overshoots from the reverse current coming from the Hard Disk Drive motor. Testing with
the actual unit may show that these capacitors can be reduced for cost reduction.
Page 10 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
8 Transformer Specification
8.1
Electrical Diagram
1
WD#1
Cancellation
12
11T #29 x 4
4T # 29
WD#8
30V O/P
NC
First
Half Primary
11
3
WD#2
22T #29 x 2
2
Shield
1T CU Foil
1
WD#9
Bias
4T # 26 x 2
WD#6
12V O/P
8
WD#5
5
1T CU Foil
5V O/P
7T #29
7
6
WD#4
1
WD#10
Second
Half Primary
23V O/P
6T # 29
10
WD#3
WD#7
2T CU Foil
22T #29 x 2
3.3V O/P
9
3
Figure 4 – Transformer Electrical Diagram
8.2
Electrical Specifications
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage Inductance
Page 11 of 30
1 second, 60 Hz, from Pins 1 - 6 to Pins 7 -12
Pins 1-2, all other windings open, measured at
132 kHz, 0.4 VRMS
Pins 1-2, all other windings open
Pins 1-2, with Pins 7-12 shorted, measured at
132 kHz, 0.4 VRMS
3000 VAC
298 uH,
-10/+10%
500 kHz (Min.)
6 µH (Max.)
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DER-98
8.3
September 12, 2005
Materials
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
8.4
41W (53W pk) DVR
Description
Core: PC40 EER28L
Bobbin: BEER28L Horizontal
Magnet Wire: #29 AWG
Magnet Wire: #26 AWG
WD#3, CU Foil: see paragraph 8.4.1 for specification
WD#4&5 CU Foil: see paragraph 8.4.2 for specification
Tape: Margin 3 mm
Tape: 3M 1298 Polyester Film, 15.8mm wide
Tape: 3M 1298 Polyester Film, 22mm wide
Teflon Tube
Transformer Build Diagram
WD#10 Second
Half Primary
1
3
WD#9 Bias
6
5
Margin Tape
11
WD#8 30V O/P
12
10
11
8
WD#6 & WD7 12V
&23V O/P
10
8
7
9
WD#4 & WD#5
3.3V & 5V O/P
1
3
WD#3 Shield
2
WD#2 First Half
Primary
WD#1 Cancellation
1
Figure 5 – Transformer Build Diagram
Page 12 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
8.4.1 WD#3 Copper Foil build diagram:
Cu Foil 2mil; 16mm W x 49mm L
1-layer tape folded
47mm
29 AWG
Figure 6 – Copper Foil Build Diagram
8.4.2 WDG#4 & #5 Copper Foil build diagram:
Cu Foil 2mil; 15.5mm W x 153mm L
1-layer tape folded
52mm
26 AWG X 2
97mm
26 AWG X 2
26 AWG X 4
Start from this
end, reverse
wind
Figure 7 – Copper Foil Build Diagram
Page 13 of 30
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DER-98
8.5
41W (53W pk) DVR
September 12, 2005
Transformer Construction
Bobbin Preparation
Teflon Tube
Margin Tape
WD#1 Cancellation
Insulation
WD#2
Fist Half Primary
Insulation
WD #3
Shield
Insulation
Margin Tape
WD #4 & WD #5
Insulation
WD #6
WD #7
WD #8
Insulation
WD #9
Insulation
WD #10
Insulation
Finish
Page 14 of 30
Pin1 side of the bobbin orients to the left hand side. The machine spins
clock-wise looking from right to left.
All winding terminations shall be applied with item [10]
Wind item [7] at the each pin side of the bobbin to match the height of the
first half primary windings.
Start on Pin 1, wind 11 turns quad-filar of item [3] from left to right. Wind
th
with tight tension. Cut the wires after finishing 11 turns. Overall, total 11
turns winding should be well fit the entire length of the bobbin.
2 Layers of tape [8] for insulation
Start on pin 2, wind 22 turns of item [3] from left to right. After finishing the
22th turns, All the wires should be well fit the entire length of the bobbin.
Bring the lead back to the left side and finish it on Pin 3.
1 Layer of tape [8] for insulation.
Start at Pin 1, wind 1 turns of item [5]. Clock-wise wind with tension.
Apply a small piece tape to secure the end of the foil.
3 Layers of tape [9] for insulation.
Wind item [7] at the each pin side of the bobbin to match the height of the
secondary windings.
Start at pin 9, anti-clock-wise wind 2 turns of item [6]. Wind with tight.
Finish the middle termination to pin 7, then continue to wind the last turn
and finish it on pin 8. Apply a piece of tape to secure the end of the foil
1 Layer of tape [8] for insulation.
Start at pin 10, wind 4 turns bifilar of item [4] from right to left. Wind
uniformly, in a single layer across entire bobbin evenly. Bring the wire
back and finish on pin 8.
In the same layer, start at pin 11, wind 6 turns of item [3] from right to left.
Wind between the wire gaps of the previous winding, in a single layer
across entire bobbin evenly. Bring the wire back and finish on pin 10.
In the same layer, start at pin 12, wind 4 turns of item [3] from right to left.
Wind uniformly, in a single layer across entire bobbin evenly. Bring the
wire back and finish on pin 11.
3 Layers of tape [9] for insulation.
Start on Pin 5, wind 7 turns item [3] from left to right. Wind with tight
th
tension and scattered across the entire bobbin evenly. After finishing 7
turn, bring the wire back and finish it on Pin 6.
2 Layer of tape [8] for insulation.
Start on pin 3, wind 22 turns of item [3] from left to right. After finishing the
th
22 turns, All the wires should be well fit the entire length of the bobbin.
Bring the lead back to the left side and finish it on Pin 1.
3 Layers of tape [9] for insulation.
Grind the core to get 298uH. Secure the core with tape.
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DER-98
8.6
41W (53W pk) DVR
September 12, 2005
Transformer Spreadsheets
ACDC_TOPSwitchGX_032204 INPUT
INFO
INFO
; Rev.1.9; Copyright Power
OUTPU OUTPU UNIT
T
T
TOP_GX_FX_032204.xls: TOPSwitch-GX/FX
Continuous/Discontinuous Flyback Transformer Design
Integrations Inc. 2004
Spreadsheet
Customer
ENTER APPLICATION VARIABLES
VACMIN
85
Volts
Minimum AC Input Voltage
VACMAX
265
Volts
Maximum AC Input Voltage
50
Hertz
AC Mains Frequency
VO
5
Volts
Output Voltage
PO
53
Watts
Output Power
n
0.7
Z
0.5
VB
15
tC
3
fL
Efficiency Estimate
Loss Allocation Factor
Volts
Bias Voltage
mSecon Bridge Rectifier Conduction Time Estimate
ds
CIN
150
uFarads Input Filter Capacitor
ENTER TOPSWITCH-GX VARIABLES
TOP-GX
TOP246
Chosen Device
TOP246 TOP246 Power
Univers 115 Doubled/230V
al
Out
KI
Power
90W
125W
Out
1
External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for
lower ILIMIT)
ILIMITMIN
ILIMITMAX
Frequency (F)=132kHz,
2.511
2.511 Amps
Use 1% resistor in setting external ILIMIT
2.889
2.889 Amps
Use 1% resistor in setting external ILIMIT
F
Full (F) frequency option - 132kHz
(H)=66kHz
fS
132000 132000 Hertz
fSmin
124000 124000 Hertz
fSmax
140000 140000 Hertz
TOPSwitch-GX Switching Frequency: Choose between 132 kHz and
66 kHz
VOR
TOPSwitch-GX Minimum Switching Frequency
TOPSwitch-GX Maximum Switching Frequency
80
Volts
Reflected Output Voltage
VDS
13
Volts
TOPSwitch on-state Drain to Source Voltage
VD
0.5
Volts
Output Winding Diode Forward Voltage Drop
VDB
0.7
Volts
Bias Winding Diode Forward Voltage Drop
KP
0.47
Ripple to Peak Current Ratio (0.4 < KRP < 1.0 : 1.0< KDP<6.0)
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type
eer28
Core
EER28
Bobbin
EER28_
EER28
P/N:
PC40EER28-Z
EER28_BOBBIN
P/N:
BEER-28-1112CPH
BOBBIN
AE
0.821
LE
6.4
0.821 cm^2
AL
2870
2870 nH/T^2
BW
16.7
16.7 mm
6.4 cm
mm
Core Effective Cross Sectional Area
Core Effective Path Length
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
M
3
Safety Margin Width (Half the Primary to Secondary Creepage
L
2
Number of Primary Layers
NS
3
Number of Secondary Turns
Distance)
Page 15 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
DC INPUT VOLTAGE PARAMETERS
VMIN
86
86 Volts
Minimum DC Input Voltage
VMAX
375
375 Volts
Maximum DC Input Voltage
DMAX
0.52
0.52
Maximum Duty Cycle
IAVG
0.88
0.88 Amps
Average Primary Current
IP
2.20
2.20 Amps
Peak Primary Current
IR
1.03
1.03 Amps
Primary Ripple Current
IRMS
1.24
1.24 Amps
Primary RMS Current
CURRENT WAVEFORM SHAPE PARAMETERS
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP
298
298 uHenrie Primary Inductance
NP
44
44
NB
9
9
s
Primary Winding Number of Turns
Bias Winding Number of Turns
ALG
156
156 nH/T^2
BM
1830
1830 Gauss
Maximum Flux Density at PO, VMIN (BM<3000)
BP
2401
2401 Gauss
Peak Flux Density (BP<4200)
430
430 Gauss
BAC
Gapped Core Effective Inductance
AC Flux Density for Core Loss Curves (0.5 X Peak to Peak)
ur
1780
1780
Relative Permeability of Ungapped Core
LG
0.62
0.62 mm
Gap Length (Lg > 0.1 mm)
BWE
21.4
21.4 mm
Effective Bobbin Width
OD
0.49
0.49 mm
Maximum Primary Wire Diameter including insulation
INS
0.07
0.07 mm
Estimated Total Insulation Thickness (= 2 * film thickness)
DIA
0.43
0.43 mm
Bare conductor diameter
AWG
26
26 AWG
CM
256
256 Cmils
Primary Wire Gauge (Rounded to next smaller standard AWG value)
CMA
207
207 Cmils/A Primary Winding Current Capacity (200 < CMA < 500)
Bare conductor effective area in circular mils
mp
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT)
Lumped parameters
ISP
32.03
32.03 Amps
Peak Secondary Current
ISRMS
17.18
17.18 Amps
Secondary RMS Current
IO
10.60
10.60 Amps
Power Supply Output Current
IRIPPLE
13.52
13.52 Amps
Output Capacitor RMS Ripple Current
CMS
3437
3437 Cmils
Secondary Bare Conductor minimum circular mils
14
14 AWG
AWGS
Secondary Wire Gauge (Rounded up to next larger standard AWG
value)
DIAS
1.63
1.63 mm
Secondary Minimum Bare Conductor Diameter
ODS
3.57
3.57 mm
Secondary Maximum Outside Diameter for Triple Insulated Wire
INSS
0.97
0.97 mm
Maximum Secondary Insulation Wall Thickness
563
563 Volts
Maximum Drain Voltage Estimate (Includes Effect of Leakage
PIVS
31
31 Volts
Output Rectifier Maximum Peak Inverse Voltage
PIVB
89
89 Volts
Bias Rectifier Maximum Peak Inverse Voltage
VOLTAGE STRESS PARAMETERS
VDRAIN
Inductance)
Page 16 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output
VO1
IO1
3.3
1.500
PO1
VD1
4.95
IRIPPLE1
Output DC Current
Volts
2.07
ISRMS1
Output Voltage
Amps
4.95 Watts
0.5
NS1
Volts
2.07
Output Winding Number of Turns
2.432
2.432 Amps
1.91
1.91 Amps
PIVS1
21
21 Volts
CMS1
486
486 Cmils
23
23 AWG
AWGS1
Output Power
Output Diode Forward Voltage Drop
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)
DIAS1
0.58
0.58 mm
Minimum Bare Conductor Diameter
ODS1
5.16
5.16 mm
Maximum Outside Diameter for Triple Insulated Wire
2nd output
VO2
12.0
Volts
Output Voltage
IO2
0.700
Amps
Output DC Current
PO2
VD2
8.40
8.40 Watts
0.5
NS2
Volts
6.82
ISRMS2
IRIPPLE2
6.82
Output Winding Number of Turns
1.135
1.135 Amps
0.89
0.89 Amps
PIVS2
71
71 Volts
CMS2
227
227 Cmils
26
26 AWG
AWGS2
Output Power
Output Diode Forward Voltage Drop
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)
DIAS2
0.41
0.41 mm
Minimum Bare Conductor Diameter
ODS2
1.57
1.57 mm
Maximum Outside Diameter for Triple Insulated Wire
3rd output
VO3
22.0
Volts
Output Voltage
IO3
0.100
Amps
Output DC Current
PO3
VD3
2.20
2.20 Watts
0.7
Volts
Output Power
Output Diode Forward Voltage Drop
NS3
12.38
12.38
Output Winding Number of Turns
ISRMS3
0.162
0.162 Amps
Output Winding RMS Current
IRIPPLE3
0.13
0.13 Amps
Output Capacitor RMS Ripple Current
PIVS3
128
128 Volts
Output Rectifier Maximum Peak Inverse Voltage
CMS3
32
32 Cmils
Output Winding Bare Conductor minimum circular mils
AWGS3
34
34 AWG
Wire Gauge (Rounded up to next larger standard AWG value)
DIAS3
0.16
0.16 mm
Minimum Bare Conductor Diameter
ODS3
0.86
0.86 mm
Maximum Outside Diameter for Triple Insulated Wire
Page 17 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency.
9.1
Line and Load Regulation
The test was done at 85 VAC and 265 VAC input, E-loads were used for the test.
Vac
Input
85V
265V
3.3V
5V
12V
23V
30V
VO/P (V)
IO/P (A)
VO/P (V)
IO/P (A)
VO/P (V)
IO/P (A)
VO/P (V)
IO/P (A)
VO/P (V)
IO/P (A)
3.325
3.31
3.39
3.18
3.15
3.26
3.26
3.25
3.26
3.29
3.238
3.3
3.36
3.19
3.17
3.26
3.26
3.25
3.24
3.29
1.5
1
0.5
1.5
1.5
1.5
1.5
1.5
1.5
0.375
1.5
1
0.5
1.5
1.5
1.5
1.5
1.5
1.5
0.375
5.01
5.01
5.01
5.02
5.03
5.01
5.01
5.01
5.01
5.06
5.01
5.01
5.01
5.02
5.03
5.01
5.01
5.01
5.01
5.06
2
2
2
1
0.5
2
2
2
2
0.5
2
2
2
1
0.5
2
2
2
2
0.5
12.62
12.64
12.62
12.3
12.12
12.87
13.02
12.7
12.7
12.35
12.35
12.47
12.46
12.22
12.09
12.67
12.89
12.48
12.47
12.35
2
2
2
2
2
1
0.5
2
2
0.5
2
2
2
2
2
1
0.5
2
2
0.5
23.5
23.57
23.54
22.97
22.63
23.69
23.65
23.94
23.68
22.8
22.80
23.26
23.22
22.76
22.49
23.24
23.29
23.94
23.23
22.78
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.25
0.5
0.125
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.25
0.5
0.125
31.0
31
30.9
30.2
29.7
31.16
31.1
31.29
33.8
30.5
30.5
30.6
30.6
30
29.7
30.7
31.8
31.29
31.5
30.4
0.08
0.08
0.08
0.08
0.08
0.08
0.08
0.08
20
20
0.08
0.08
0.08
0.08
0.08
0.08
0.08
0.08
20
20
Page 18 of 30
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DER-98
9.2
41W (53W pk) DVR
September 12, 2005
Efficiency
Efficiency vs Load
0.9
Efficiency
0.8
0.7
115V
0.6
230V
0.5
0.4
0.3
0%
20%
40%
60%
80%
100%
120%
Load Percentage
Figure 8 – Efficiency
9.3
Overvoltage Protection
Test Result:
Under the all line and load conditions, short out the regulation optocoupler
LED to simulate a loop failure. The power supply goes into auto restart
mode, until the fault is removed.
Comment:
PASS
Page 19 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
10 Thermal Performance
Test Condition: The power supply was set on the bench and the all the loads were at full
load except 12 V loading at 1 A. The total output power was 41 W.
Temperature (°C)
Item
85 VAC
265 VAC
(°C)
25
Ambient (°C)
TOP246Y (U1)
Page 20 of 30
80
78
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DER-98
41W (53W pk) DVR
September 12, 2005
11 Control Loop Measurements
The power supply is loaded at full load 53 W to show worst case.
11.1 110 VAC Maximum Continuous Load
Figure 9 – Gain-Phase Plot, 110 VAC, 53W Steady State Load.
Vertical Scale: Gain = 10 dB/div, Phase = 30°/div.
Crossover Frequency = 938 Hz Phase Margin = 78.4°
11.2 230 VAC Maximum Continuous Load
Figure 10 – Gain-Phase Plot, 230 VAC, 53W Steady State Load.
Vertical Scale: Gain = 10 dB/div, Phase = 30°/div.
Crossover Frequency = 1.19 kHz, Phase Margin = 87.28°
Page 21 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
12 Waveforms
Waveforms were taken at 25oC. All outputs are loaded at full load, total 53 W.
12.1 Drain Voltage and Current, Normal Operation
Figure 11 – 85 VAC, Full Load.
Lower: IDRAIN, 1 A / div
Upper: VDRAIN, 200 V, 2 µs / div
Figure 12 – 265 VAC, Full Load
Lower: IDRAIN, 1 A / div
Upper: VDRAIN, 200 V, 2 µs / div
12.2 Output Voltage Start-up Profile
12V
12V
5V
5V
3.3V
3.3V
Figure 13 – Start-up Profile, 85 VAC
1 V / div for 3.3 V & 5 V, 2 V / div for 12 V,
50 ms / div.
Page 22 of 30
Figure 14 – Start-up Profile, 265 VAC
1 V / div for 3.3 V & 5 V, 2 V / div for 12V,
50 ms / div.
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DER-98
41W (53W pk) DVR
September 12, 2005
30V
30V
23V
23V
Figure 15 – Start-up Profile, 85 VAC
5 V / div for 23 V & 30 V, 50 ms / div.
Figure 16 – Start-up Profile, 265 VAC
5 V / div for 23 V & 30 V, 50 ms / div.
12.3 Drain Voltage Start-up Profile
Figure 17 – 90 VAC Input. Lower: IDRAIN, 1 A / div
Upper: VDRAIN, 200 V, 50 ms / div.
Page 23 of 30
Figure 18 – 265 VAC Input. Lower: IDRAIN, 1 A / div
Upper: VDRAIN, 200 V, 50 ms / div.
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DER-98
41W (53W pk) DVR
September 12, 2005
13 Output Ripple Measurements
13.1.1 Ripple Measurement Technique
For DC output ripple measurements, a modified oscilloscope test probe must be utilized in
order to reduce spurious signals due to pickup. Details of the probe modification are
provided in Figure 19 and Figure 20.
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 19 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 20 – Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe
ground for ripple measurement, and two parallel decoupling capacitors added)
Page 24 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
13.1.2 Measurement Results
The power supply was at 41W resistor load. 25Deg.C ambient.
Figure 21 – 85 VAC, 3.3 V, 5 ms, 20 mV / div
Figure 22 – 265 VAC, 3.3 V, 5 ms, 10 mV / div
Figure 23 – 85 VAC, 5 V, 5 ms, 20 mV / div
Figure 24 – 265 VAC, 5 V, 5 ms, 10 mV / div
Page 25 of 30
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DER-98
41W (53W pk) DVR
Figure 25 – 85 VAC, 12V, 5 ms, 50 mV / div
Figure 27 – 85 VAC, 23V, 5 ms, 100 mV / div
Page 26 of 30
September 12, 2005
Figure 26 – 265 VAC, 12V, 5 ms, 10 mV / div
Figure 28 – 265 VAC, 23V, 5 ms, 10 mV / div
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DER-98
41W (53W pk) DVR
Figure 29 – 85 VAC, 30V, 5 ms, 100 mV / div
Page 27 of 30
September 12, 2005
Figure 30 – 265 VAC, 30V, 5 ms, 10 mV / div
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DER-98
41W (53W pk) DVR
September 12, 2005
14 Conducted EMI
EMI was tested at room temperature and 230 VAC input. The power supply was at 41W
resistor load. Two conditions were tested. (1) Secondary return connected to LISN ground
(worst case), and (2) with no connection. Blue line is QP, Red line is AVG.
14.1 230V High Line EMI
Figure 31 – Line, Secondary Grounded
Figure 32 – Neutral, Secondary Grounded
Figure 33 – Line, Secondary Floating
Figure 34 – Neutral, Secondary Floating
Page 28 of 30
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DER-98
41W (53W pk) DVR
September 12, 2005
15 Revision History
Date
September 12, 2005
Page 29 of 30
Author
DZ
Revision
1.0
Description
Initial release
Reviewed
JC / AM / VC
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DER-98
41W (53W pk) DVR
September 12, 2005
For the latest updates, visit our Web site: www.powerint.com
Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your
use of any information, device or circuit described herein nor does it convey any license under its patent rights or the
rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL
WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS
FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
PATENT INFORMATION
The products and applications illustrated herein (including circuits external to the products and transformer construction)
may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications
assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power
Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations.
© Copyright 2004, Power Integrations.
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