Power EPR-18 Engineering prototype report for ep-18 10 w, multiple output, isolated power supply with Datasheet

Title
Engineering Prototype Report for EP-18
10 W, Multiple Output, Isolated Power
Supply with TOPSwitch-GX
Input Voltage
Key
Specifications
Output Voltages and
Current
Output Power
Efficiency
P.I. Device
85-265 VAC
3.3 V, 1.5 A
5 V, 0.9 A
30 V, 0.03 A
10 W
70% minimum
TOP243P (TOPSwitch-GX)
Target
Applications
High Speed Digital Modems / Telecom
Document
Number
EPR-18
Date
05-Dec-2002
Revision
1.3
Features
•
•
•
•
•
•
•
•
•
•
Low cost (low component count with single sided printed circuit board)
Low conducted EMI: meets CISPR22B/EN55022B without requiring a Y capacitor
Meets EN/UL 1000-4-5 CLASS 4 (4 kV), using line overvoltage protection feature
Designed to IEC60950 safety standard requirements
Ultra-low earth leakage current (<1 µA @ 265 VAC, 50/60 Hz) eliminates line frequency audio
hum in voice applications (“ground loops”)
Compact Design (L = 113 mm, W = 39 mm, H = 25 mm)
High efficiency (≥70% at 85 VAC)
Line undervoltage shutdown prevents turn-off output glitches
Line overvoltage shutdown provides extended line swell protection
Hysteretic thermal shutdown provides automatic supply recovery after fault removal
Power Integrations, Inc.
5245 Hellyer Avenue, San Jose, CA 95138 USA
Tel: +1 408 414 9200 Fax: +1 408 414 9201
Applications Hotline: (408) 414-9660
http://www.powerint.com
10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
Table Of Contents
1
2
3
4
5
6
7
Introduction.................................................................................................................3
Power Supply Specification ........................................................................................4
Schematic...................................................................................................................5
Circuit Description ......................................................................................................6
PCB Layout ................................................................................................................9
Bill Of Materials ........................................................................................................10
Transformer Specification.........................................................................................11
7.1
Electrical Specifications.....................................................................................11
7.2
Materials............................................................................................................11
7.3
Transformer Build Diagram ...............................................................................12
7.4
Transformer Construction..................................................................................12
7.5
Design Notes.....................................................................................................13
7.6
Transformer Sources.........................................................................................13
8 Transformer Spreadsheets .......................................................................................15
9 Performance Data ....................................................................................................17
9.1
Efficiency ...........................................................................................................17
9.2
Regulation .........................................................................................................18
9.2.1
Load ...........................................................................................................18
9.2.2
Line ............................................................................................................18
9.2.3
Cross-Regulation Table..............................................................................19
10
Thermal Performance ...........................................................................................20
11
Waveform Scope Plots .........................................................................................21
12
Load Transient Response (75% to 100% Load Step) ...........................................22
13
Conducted EMI .....................................................................................................23
14
Surge Voltage .......................................................................................................25
14.1 Differential = Line-to-Line (L-N), 2 Ω Source Impedance. .................................25
14.2 Common Mode = Line-to-Ground (L-GND, N-GND), 12 Ω Source Impedance .25
15
Revision History ....................................................................................................26
Important Note:
Although the EP-18 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.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 2 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
1 Introduction
This document is an engineering report describing a low cost, isolated converter (EP-18)
for a High Speed Digital Modem application.
Included are the power supply specification, schematic, bill of materials, transformer
documentation, printed circuit layout, and performance data.
Figure 1 – EP-18 Populated Circuit Board (LxWxH: 113 mm x 39 mm x 25mm).
Page 3 of 28
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
2 Power Supply Specification
Description
Input
Voltage
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
Total Output Power
Continuous Output Power
Efficiency
Symbol
Min
VIN
85
VOUT1
VRIPPLE1
IOUT1
VOUT2
VRIPPLE2
IOUT2
VOUT3
VRIPPLE3
IOUT3
3.13
POUT
η
0.3
4.75
0.3
Typ
3.30
1.5
5.00
Max
Units
Comment
265
VAC
50/60 Hz
3.47
30
3.00
5.25
50
V
mV
A
VDC
mV
A
VDC
mV
A
0.9
30
150
0.01
0.03
10
±5% Total
Peak to Peak, 20 MHz BW
±5% Total
Peak to Peak, 20 MHz BW
±10% Total
Peak to Peak, 20 MHz BW
70
W
%
Full Load, 25 C, VIN(MIN)
2
kV
IEC/UL 1000-4-5 Class 4
4
kV
IEC/UL 1000-4-5 Class 4
50
o
External Ambient Range
70
o
Internal Case Ambient Range
Full Load
o
Environmental
Surge (differential, 2 Ω)
Surge (common mode, 12 Ω)
Ambient Temperature
Internal Ambient Temperature
Line-Line
Line/LinePE
TAMB_EXT
TAMB_INT
0
25
C
C
Conducted EMI*
Meets CISPR22B with secondary connected to protective earth ground (PE)
(worst case condition)
Safety
Designed to exceed IEC60950 requirements
*Conducted EMI is met without a safety rated Y class capacitor bridging primary and
secondary. This provides an ultra-low earth leakage current (<1µA at 265 VAC,
50/60 Hz) necessary to eliminate line frequency audio hum in voice applications
(“ground loops”).
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 4 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
3 Schematic
Figure 2 - EP-18 Schematic.
Page 5 of 28
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
4 Circuit Description
The EP-18 is a low-cost flyback switching power supply designed for high speed digital
modem applications using the TOP243P integrated circuit. It offers a low cost solution
with emphasis on low EMI and ultra-low earth leakage current (no Y cap).
The circuit schematic details a 10 W, 3 output (3.3 VDC, 5 VDC and 30 VDC) power
supply that operates from an 85 VAC to 265 VAC input. The high efficiency (>70%)
allows the power supply to operate within specifications at elevated ambient temperature.
The AC input is rectified and filtered by D1 to D4 and C1 to create a high voltage DC bus
that is connected to transformer T1. The other side of T1 is driven by the high-voltage
MOSFET of TOP243P1 (U1). Fuse F1 protects against primary-side components
failures, while U1 protects against secondary components failures, and
overloaded/shorted outputs.
The combined value of the line sensing resistors R2 and R3, connected to the MULTIFUNCTION (M) pin of U1, sets the undervoltage and overvoltage thresholds and
provides a line feed forward function.
On increasing line voltage, the power supply is inhibited until the undervoltage (UV)
threshold is reached (~100 VDC). On reducing line voltage, the UV function turns off the
power supply when the line input voltage is below the UV threshold and the output goes
out of regulation. This allows the power supply to continue operating at input voltages
significantly below the UV threshold until output regulation is lost, but eliminates output
glitches by preventing restart until the input voltage goes back above the UV threshold.
The overvoltage function turns off the power supply if the input voltage exceeds
approximately 450 V. In the off-state, the power supply can withstand severe line
transients or extended line swell conditions without damage. The supply resumes
operation when the input voltage falls below the overvoltage threshold.
The line feed forward function independently modulates the duty cycle of U1 to reject the
AC line frequency ripple component of the input voltage, reducing the line frequency
ripple at the output of the supply. The output ripple specifications can be met without
increased control loop gain since line feed forward operates independent of the main
control loop. This simplifies the design of the power supply control loop.
A low cost RCD (R1, C2, R9 and D5) snubber circuit limits the turn-off voltage spike
(caused by the leakage inductance) to a safe level on the DRAIN pin of U1. Resistor R9
is required in series with the slow recovery diode (D5) to reduce the diode reverse
1
The “P” and “G” packages allow either line sensing or external current limit programming through the M
pin. “Y” and “R” packages allow both functions via the L and X pins. Reducing the current limit in this
design would allow a smaller transformer to be used, if desired.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 6 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
recovery spike and damp the subsequent oscillations which might allow the drain to ring
below source at low line.
The bias winding is rectified and filtered by D6 and C11 to power U1. Capacitor C3 is
used to decouple the CONTROL pin, determine the auto-restart frequency and together
with R4, forms part of the control loop compensation.
The secondary winding is rectified and filtered by D7, R5, C4 (30 V) D8, C5 (5 V) and D9,
C7, C8 (3.3 V), with additional switching frequency ripple and high frequency spike noise
filtering provided by L2, C8 (5 V) and L3, C9 (3.3 V) to give the DC outputs.
The choice of Schottky diodes for the 3.3 V and 5 V outputs was driven by both voltage
regulation and efficiency considerations. Resistor R5 limits the diode current at start-up
and avoids peak charging of the 30 V output. If a fusible resistor is used, R5 can provide
short circuit protection for this output.
The snubber (C13 and R8) reduces the 10 MHz to 30 MHz conducted EMI due
secondary leakage inductance. The current through the pre-load resistor R13 adds to the
spec minimum load to keep the 30 V output in regulation. The 3.3 V and 5 V output
voltages are determined by the voltage set at the adjust pin of U3 (shunt regulator) by the
voltage divider formed by R10, R11 and R12. The current through R12 (250 µA) sets the
output voltages, while the current contribution of R10 and R11 (250 µA total) sets the
regulation band for 3.3 V and 5 V outputs, respectively. Other output voltages are
possible by adjusting the transformer turns ratios, choosing the output diodes forward
voltage drops and voltage divider settings. Optocoupler U2 applies the feedback signal
from U3 to the CONTROL pin of U1. Resistor R6 is used to set the overall gain of the
supply control loop, while R7 provides bias current for U3. Capacitor C10 provides
frequency compensation for U3 stabilizing the power supply control loop. Capacitor C14
is used to close the feedback loop (bypassing U3) through optocoupler U2 during startup, before U3 takes over the control loop. The ability to close the feedback loop in
conjunction with the built-in soft-start feature of TOPSwitch-GX completely controls the
start-up drain current profile, preventing transformer saturation and output overshoot.
The 3.3 V and 5 V secondary layout switching loops are minimized and, along with
closely coupled transformer secondary windings, achieve low secondary leakage
inductance and in turn, good cross-regulation. Optimizing the number of primary turns
minimizes leakage. This also reduces the number of primary layers and improves
primary to secondary coupling.
The power supply meets IEC60950/UL1950 safety requirements. Primary-to-secondary
isolation is assured by using parts/materials (opto/transformer insulation) with the correct
level of isolation and creepage distances (opto slot/transformer bobbin).
The power supply passed IEC/UL 1000-4-5, Class 4 line surge test (Class 3 only is
required). All three outputs had monitor LEDs that showed no output disruption during
the 90 high voltage surge pulses of Class 3. During Class 4 testing the outputs were
Page 7 of 28
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
disrupted for one second (LEDs blinked indicating the operation of the overvoltage
shutdown feature) when applying the 2 kV, 2 Ω differential pulse and the 4 kV, 2 Ω
differential pulses (L1/GND, L2/GND) and were unaffected during the 4 kV, 12 Ω
common-mode pulses (L1, L2/GND).
The switching frequency jitter of TOP243 (U1) allows the unit to meet worldwide
conducted EMI standards using a low cost, common-mode inductor (L1) in combination
with a small value capacitor (C15). Careful transformer construction and PCB layout
eliminate the need for a Y-rated capacitor between primary and secondary. Removal of
the Y cap is necessary in voice applications to eliminate line frequency audio hum
(“ground loops”). The common-mode inductance of L1 and the transformer construction
attenuate common-mode conducted emission currents caused by the switching
waveform on the DRAIN of U1, charging and discharging various stray capacitances.
The differential inductance of L1 together with C15 attenuate differential-mode emission
currents caused by the fundamental and harmonics of the primary current waveform.
The power supply passed the conducted EMI test (CISPR22B). The extended scan (to
100 MHz) was performed to detect high frequency peaks that could cause problems in
radiated emissions. A vertical and a horizontal bobbin transformer were both evaluated
for EMI. The vertical bobbin had slightly lower EMI and was selected for the final
prototype.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 8 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
5 PCB Layout
Figure 3 – EP18 Printed Circuit Layout. Actual Size Board (L = 113 mm, W = 39 mm, H = 25 mm).
For the drain-to-source voltage waveforms, connect the high voltage probe tip to TP2 and
the probe ground to test point TP1.
For switching current waveforms, add a wire loop in the provided holes and cut open the
copper trace. Use a Tektronix A6302 current probe and AM503 current probe amplifier
(with TM501 power module) or equivalent.
Page 9 of 28
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
6 Bill Of Materials
Bill Of Materials
Item Qty. Ref.
1
1
C1
2
1
C2
Description
33 µF, 400 V,105 °C
1 nF, 1 kV, 6.5 mm,
LS = 6.4mm
C3
47 µF, 10 V
C4
47 µF, 10 V
C5-C7
820 µF 16 V /
1000 µF, 16 V
C8
100 µF, 10 V
C9
150 µF, 6.3 V
C10,11 0.1 µF, 50 V
C12
10 µF, 50 V
C13
2200 pF, 100 V, multilayer cer.
C14
1 µF, 50 V, ceramic
C15
0.1 µF 250 VAC, X1
D1-D5
1 A, 1000 V
D6
0.15 A, 75 V, 4 ns
D7
1 A, 200 V, 50 ns
D8
3 A, 60 V, Schottky
D9
5 A, 40 V, Schottky
F1
250 VAC, 3.15 A
J1
HEADER 3
J2
HEADER 6
L1
20 mH, 0.4 A
L2, L3
3.3 µH, 2.66 A
L4
10 µH, 130 mA
R1
150 kΩ, 1/2 W
R2, R3 1 MΩ, 1/4 W
R4
6.8 Ω, 1/4 W
R5,R8
10 Ω, 1/4 W
R6
75 Ω, 1/4 W
R7
1 kΩ, 1/4 W
R9
100 Ω, 1/4 W
R10
15.4 kΩ ±1%, 1/4 W
R11,R12 10.0 kΩ ±1%, 1/4 W
R13
12 kΩ, 1/4 W
T1
EI25 XFMR (custom)
U1
TOPSwitch-GX
U2
Optocoupler
U3
Shunt Regulator, 2.5 V 1%
Part number
KMX400VB33
Manufacturer
UCC
Philips Centra
3
4
5
1
1
3
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
1
2
1
1
1
1
5
1
1
1
1
1
1
1
1
2
1
1
2
1
2
1
1
1
1
2
1
1
1
1
1
KME10VB47RMX11LL
LXZ50VB47RM6X11LL
EEU-FC1C821 /
LXZ216VB102M10X20LL
LXZ10VB101M5X11LL
LXZ6.3VB151M5X11LL
K104M15Z5UF5TH5
EEU-FC1H100L
C315C222K1R5CA
F1772-410-2000
1N4007
1N4148
UF4003/UF1003
SB360
SB540
19372K
26-48-1031
26-48-1061
SS11V-05230
822MY-3R3M
UCC
UCC
Panasonic
UCC
UCC
UCC
BC
Panasonic
Kemet
Any
Vishay
General Semi.
General Semi.
General Semi.
General Semi.
General Semi.
Wickman
Molex
Molex
Tokin
Toko
SIL6008 Rev D
TOP243P
LTV817A
LM431BCZ
Any
Any
Any
Any
Any
Any
Any
Any
Any
Any
HiCal
Power Integrations
Liteon
National Semiconduct
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 10 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
7 Transformer Specification
Figure 4 - EP18 Transformer Electrical Diagram.
7.1
Electrical Specifications
Electrical Strength
Primary Inductance
1 minute, 60 Hz, from Pins 1-5 to Pins 6-10
Pins 1-2, all windings open, 130 kHz
measurement frequency
Resonant Frequency
Pins 1-2, all windings open
Primary Leakage Inductance
Pins 1-2, Pins 6-10 shorted, 130 kHz
measurement frequency
7.2
Item
[1]
[2]
[3]
[4]
[5]
[6]
3000 VAC
1180 µH +/-10%
0.5 MHz
minimum
30 µH maximum
Materials
Description
Core: EI25, Nippon Ceramic FEI-25, NC-2H material or equivalent, gapped for AL of 351 nH/T2.
Note: Core longer than standard EI25.
Bobbin: YW-360-02B by YIH-HWA Enterprise, 10 PIN, with secondary-side pedestal.
Pin 3 removed.
Magnet Wire: #29 AWG Heavy Nyleze
Triple Insulated Wire (TIW): #26 AWG
Tape: 3M 1298 Polyester Film (white) 10.58 mm wide by 2.2 mm thick
Varnish
Page 11 of 28
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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10 W, Multiple Output, Isolated Power Supply
7.3
05-Dec-2002
Transformer Build Diagram
Figure 5 – EP18 Transformer Build Diagram.
7.4
Transformer Construction
Shield
Tape Insulation
Double Primary
Layer
Tape Insulation
Bias Winding
Tape Insulation
3.3 V Winding
5 V Winding
30 V Winding
Tape Insulation
Final Assembly
Start at Pin 1. Wind 15 turns of item [3], bifilar parallel, from left to right, over entire
length of the bobbin. Finish on Pin 3.
1 Layer of tape [5] for insulation
Start at Pin 2. Wind 30 turns of item [3] from left to right over entire length of the
bobbin. Apply 2 layers of tape, item [5], for spacing. Wind remaining 28 turns in the
next layer from right to left, over entire length of the bobbin. Finish on Pin 1.
1 Layer of tape [5] for insulation.
Start at Pin 5. Wind 7 turns parallel trifilar of item [3] from left to right, uniformly over
entire width of bobbin. Finish on Pin 4.
6 Layers of tape [5] for spacing.
Start at Pin 6. Wind 2 turns parallel trifilar of item [4] from left to right, uniformly over
entire width of bobbin. Finish on Pin 7. Secure turns with 1 layer of tape.
Start at Pin 9. Wind 1 turn of item [4] from left to right over entire width of bobbin.
Finish on Pin 6. Secure turns with 1 layer of tape.
Start at Pin 10. Wind 13 of item [4] from left to right uniformly, over entire width of
bobbin. Finish on Pin 9.
3 Layers of tape [5] for insulation.
Assemble core with the “I” side on top. Secure core. Dip varnish the transformer
[6].
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 12 of 28
05-Dec-2002
7.5
Design Notes
Power Integrations Device
Frequency of Operation
Mode
Peak Primary Current
Reflected Voltage
Maximum DC Input
Minimum DC Input
7.6
10 W, Multiple Output, Isolated Power Supply
TOP243P
132 kHz
Continuous/Discontinuous
0.42 A
110 V
375 V
90 V
Transformer Sources
For information on the vendors used to source the transformers used on this board,
please visit the Power Integrations' Web site at the URL below and select “Engineering
Prototype Boards”
http://www.powerint.com/componentsuppliers.htm
Page 13 of 28
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
Figure 6 - EI25 Bobbin Drawing.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 14 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
8 Transformer Spreadsheets
Power Supply Input
VACMIN
Volts
85
Minimum AC Input Voltage
VACMAX
Volts
265
Maximum AC Input Voltage
FL
Hertz
50
TC
mSeconds
Z
N
%
AC Main Frequency
2.33
Bridge Rectifier Conduction Time Estimate
0.65
Loss Allocation Factor
75.0
Efficiency Estimate
Power Supply Outputs
Out1 Out2 Out3
Vox
Volts
3.30
5.00
Iox
Amps
1.500
0.900
30.00 Output Voltage
0.030 Power Supply Output Current
VB
Volts
12.00
Bias Voltage
IB
Amps
0.000
Bias Current
Device Variables
Device
TOP243P
PO
Watts
VDRAIN
Volts
VDS
Volts
3.6
FS
Hertz
132000
Device Switching Frequency
0.70
Ripple to Peak Current Ratio
KRPKDP
KI
10.35
Device Name
626
Total Output Power
Maximum Drain Voltage Estimate (Includes Effect of
Leakage Inductance)
Device On-State Drain to Source Voltage
1.00
External Current Limit Ratio
ILIMITEXT
Amps
0.70
Device Current Limit, External Mimimum
ILIMITMIN
Amps
0.70
Device Current Limit, Minimum
ILIMITMAX
Amps
0.80
Device Current Limit, Maximum
IP
Amps
0.42
Peak Primary Current
IRMS
Amps
0.22
Primary RMS Current
0.56
Maximum Duty Cycle
DMAX
Power Supply Components
Selection
CIN
µFarads
VMIN
Volts
33.0
90
Input Filter Capacitor
Minimum DC Input Voltage
VMAX
Volts
375
Maximum DC Input Voltage
VCLO
Volts
170
Clamp Zener Voltage
PZ
W
1.3
Estimated Primary Zener Clamp Loss
VDB
Volts
0.7
Bias Winding Diode Forward Voltage Drop
PIVB
Volts
55
Bias Rectifier Maximum Peak Inverse Voltage
Page 15 of 28
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10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
Power Supply Output
Parameters
VDx
Volts
0.5
0.5
0.7 Output Winding Diode Forward Voltage Drop
PIVSx
Volts
16
24
135 Output Rectifier Maximum Peak Inverse Voltage
ISPx
Amps
5.55
3.33
0.11 Peak Secondary Current
ISRMSx
Amps
2.50
1.50
0.05 Secondary RMS Current
IRIPPLEx
Amps
2.01
1.20
0.04 Output Capacitor RMS Ripple Current
Transformer Construction
Parameters
Core/Bobbin
EI25
Core and Bobbin Type
Core Manuf.
Generic
Core Manufacturing
Bobbin Manuf.
Generic
Bobbin Manufacturing
µHenries
LP
1177
NP
58
NB
6.68
Primary Inductance
Primary Winding Number of Turns
Bias Winding Number of Turns
AWG
AWG
CMA
Cmils/A
VOR
Volts
BW
mm
9.80
M
mm
0.0
Safety Margin Width
2.0
Number of Primary Layers
L
30
Primary Wire Gauge (Rounded to next smaller
standard AWG value)
Primary Winding Current Capacity (200 < CMA < 500)
472
110.00
Reflected Output Voltage
Bobbin Physical Winding Width
AE
cm^2
0.41
Core Effective Cross Section Area
ALG
nH/T^2
351
Gapped Core Effective Inductance
BM
Gauss
2093
Maximum Operating Flux Density
BP
Gauss
3977
BAC
Gauss
733
AC Flux Density for Core Curves
LG
mm
0.12
LL
µH
23.5
Gap Length (Lg > 0.051 for TOP22X, Lg > 0.1 for
TOP23X)
Estimated Transformer Primary Leakage Inductance
LSEC
nH
20
Peak Flux Density (Bp < 4200)
Estimated Secondary Trace Inductance
Secondary
Parameters
NSx
2.00
Rounded Down
NSx
Rounded Down Volts
Vox
Rounded Up
NSx
Rounded Up
Volts
Vox
AWGSx Range AWG
2.89
2
3.30
3
16.16 Secondary Number of Turns
16 Rounded to Integer Secondary Number of Turns
29.70 Auxiliary Output Voltage for Rounded to Integer NSx
17 Rounded to Next Integer Secondary Number of Turns
31.60 Auxiliary Output Voltage for Rounded to Next Integer
NSx
20 – 24 22 – 26 37 – 41 Secondary Wire Gauge Range (CMA range 500 –
200).
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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5.20
Page 16 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency.
TEST EQUIPMENT
INPUT:
VOLTECH (PM100) AC POWER ANALYSER.
Power Line Meter (EPD Inc.)
OUTPUT:
KIKUSUI (PLZ153W) ELECTRONIC LOAD.
9.1
Efficiency
Efficiency vs. Load
100
90
80
70
60
50
40
30
20
10
0
0.3
Efficiency (%)
Efficiency (%)
Efficiency vs. Load
85 VAC, I5 = 0.2 A
265 VAC, I5 = 0.2 A
0.5
0.7
0.9
1.1
1.3
1.5
100
90
80
70
60
50
40
30
20
10
0
0.3
85 VAC, I3.3 = 0.3 A
265 VAC, I3.3 = 0.3 A
0.4
3.3 VDC Output Load (A)
0.5
0.6
0.7
0.8
5 VDC Output Load (A)
Figure 7 - Efficiency vs. Output Load.
Efficiency vs. Line Voltage
100
90
Efficiency (%)
80
70
60
50
40
30
20
10
0
85
105
125
145
165
185
205
225
245
265
Line Voltage (VAC, 60 Hz)
Figure 8 - Efficiency vs. Input Voltage at Full Load.
Page 17 of 28
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0.9
10 W, Multiple Output, Isolated Power Supply
9.2
05-Dec-2002
Regulation
9.2.1 Load
5 VDC Regulation
(3.3 VDC @ 0.3 A, 30 VDC @ 0.002 A)
102
102
101
101
VOUT/VNOM x 100
VOUT/VNOM x 100
3.3 VDC Regulation
(5 VDC @ 2 A, 30 VDC @ 0.002 A)
100
99
98
100
99
98
97
97
96
0.3
96
0.3
0.5
0.7
0.9
1.1
1.3
1.5
0.4
0.5
0.6
0.7
0.8
0.9
5 VDC Output Load (A)
3.3 VDC Output Load (A)
Figure 9 - Load Regulation at 85 VAC.
9.2.2 Line
L in e R e g u la tio n @ F u ll L o a d
3 .3 V D C @ 1 .5 A
5 V D C @ 0 .9 A
3 0 V D C @ 0 .0 3 A
102
VOUT/VNOM x 100
101
100
99
98
97
96
95
85
105
125
145
165
185
205
225
245
265
L in e V o lta g e (V A C , 6 0 H z )
Figure 10 - Line Regulation at Full Load.
Power Integrations, Inc.
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Page 18 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
9.2.3 Cross-Regulation Table
VOUT (VDC) @ min (0), max (1) load, VIN = 85 VAC, 60 Hz
30
5
3.3
30
5
28.9
5.03
3.33
0
0
31.5
5.2
3.18
0
0
30.6
4.88
3.41
0
1
33
5.05
3.25
0
1
27.5
5.04
3.33
1
0
28.7
5.2
3.18
1
0
28.2
4.9
3.4
1
1
29.7
5.06
3.25
1
1
Min (A)
0.01
0.3
Max (A)
0.03
0.9
Page 19 of 28
3.3
0
1
0
1
0
1
0
1
0.3
1.5
33
30
27
5.25
5
4.75
3.465
3.3
3.135
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10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
10 Thermal Performance
Clamp (55 °C)
U1 (57 °C)
D8 (52 °C)
D9 (54 °C)
Figure 11 - Infrared Thermograph of EP18, 85 VAC Input, Full Load, 25 °C Ambient
Power Integrations, Inc.
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Page 20 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
11 Waveform Scope Plots
0.2 A/div
0.2 A/div
100 V/div
100 V/div
Figure 12 - Drain Current and Drain-to-source
Voltage at Full Load
(VIN = 85 VAC, 60 Hz).
Figure 13 - Drain Current and Drain-to-source
Voltage at Full Load
(VIN = 265 VAC, 60 Hz).
30 V
30 V
5V
3.3 V
Figure 14 - Output Voltage Ripple at Full Load
(VIN = 85 VAC In, 60 Hz).
Page 21 of 28
3.3 V
0.4 A / div
Figure 15 - Primary Current and Output Voltages
During Start-up at Minimum Load
(VIN = 265 VAC In, 60 Hz).
Power Integrations, Inc.
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10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
12 Load Transient Response (75% to 100% Load Step)
Transient response is measured by changing the load, at twice the input line frequency,
from 75% and 100%. The peak of the output voltage response is controlled by the output
capacitor ESR while the recovery time is controlled by the output filter and the loop
response.
5V
5V
3.3
3.3
0.5 A / div
0.5 A / div
Figure 16 - 3.3 V and 5 VDC Response to 3.3 V
Load Step 75% - 100%
(1.125 A to 1.5 A) at 85 VAC
(5 V @ 0.9 A).
Figure 17 - 3.3 V and 5 VDC Response to 5 V
Load Step 75% - 100%
(0.9 A to 0.675 A) at 85 VAC
(3.3 V @ 1.5 A).
The stability of the power supply under various line and load conditions can be confirmed
by observing the phase margin at crossover (0 dB) and the attenuation (-dB) at positive
feedback (≥360º Phase).
32dB Attenuation
0
72.8 Phase margin
Figure 18 - Worst Case Phase Margin and Gain (Full Load VAC).
Power Integrations, Inc.
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Page 22 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
13 Conducted EMI
The attached plots show worst-case EMI performance for EP-18 as compared to
CISPR22B conducted emissions limits. The scans were extended to 70 MHz or 100 MHz
to detect possible peaks that could radiate from the input/output conductors.
Figure 19 - Conducted EMI Results - Full Load, 115 VAC, Output RTN Floating.
Figure 20 - Conducted EMI Results - Full Load, 115 VAC, Output RTN Grounded to PE.
Page 23 of 28
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10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
Figure 21 - Conducted EMI Results - Full Load, 230 VAC, Output RTN Floating.
Figure 22 - Conducted EMI Results - Full Load, 230 VAC, Output Grounded to PE.
Power Integrations, Inc.
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Page 24 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
14 Surge Voltage
14.1 Differential = Line-to-Line (L-N), 2 Ω Source Impedance.
The unit exceeded the 1 kV IEC/UL 1000-4-5 Class 3 requirement (meets Class 4, 2 kV).
14.2 Common Mode = Line-to-Ground (L-GND, N-GND), 12 Ω Source Impedance
The unit exceeded the IEC/UL 1000-4-5 Class 3, 2 kV, meeting Class 4, 4 kV
requirements.
All three outputs had monitor LEDs that showed no output disruption during the 90 high
voltage surge pulses of Class 3 (FAST).
During Class 4 testing, the outputs were disrupted for one second (LEDs blinked) when
applying the 2 kV, 2 Ω differential pulse and the 4 kV, 12 Ω differential pulses (L1/GND,
L2/GND), indicating the overvoltage shutdown protection was triggered.
The outputs were unaffected during the 4 kV, 12 Ω common mode pulses (L1, L2/GND).
The unit was centered on the insulation side of a 6 in x 4 in single sided copper clad
board (1.4 mm insulation), to avoid surface or insulation breakdown during the voltage
surges.
The voltage was applied between the input terminals of the unit (L or N) and the copper
clad ground plane (GND), in the following sequence:
L (+4 kV) to GND, 5 times
L (-4 kV) to GND, 5 times
N (+4 kV) to GND, 5 times
N (-4 kV) to GND, 5 times
L, N (+4 kV) to GND, 5 times
L, N (-4 kV) to GND, 5 times
Page 25 of 28
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10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
15 Revision History
Date
20-Jun-2001
16-Jul-2001
Author
SL
SL
SL
Revision
0.1
0.2
0.3
31-Jul-2001
SL
0.4
07-Aug-2001
SL
0.5
21-Nov-2002
05-Dec-2002
PV
IM
1.2
1.3
Power Integrations, Inc.
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Description & changes
First draft
Single layer, through hole design
Implemented design review comments
Eliminated Y cap, added 2 shield
windings and output diode snubber.
Updated transformer design, test data
and pictures.
Updated EMI and thermal image.
Minor text changes
Updates after review
Page 26 of 28
05-Dec-2002
10 W, Multiple Output, Isolated Power Supply
Notes
Page 27 of 28
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10 W, Multiple Output, Isolated Power Supply
05-Dec-2002
For the latest updates, visit our Web site: www.powerint.com
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 reserves the right to make changes to its products at any time to improve reliability or
manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit
described herein, nor does it convey any license under its patent rights or the rights of others.
The PI Logo, TOPSwitch, TinySwitch and EcoSmart are registered trademarks of Power Integrations, Inc.
©Copyright 2002, Power Integrations, Inc.
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NORTH AMERICA - WEST
Power Integrations, Inc.
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+1-408-414-9200
Customer Service:
Phone: +1-408-414-9665
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Page 28 of 28