Design Example Report Title 20W Dual Output Power Supply using TOP247Y Specification Input: 85-265 VAC Output: 12V/1.25A, -14V/0.4A Application Cooking Range Author Power Integrations Applications Department Document Number DER-53 Date April 20, 2005 Revision 1.0 Summary and Features This document is an engineering prototype report describing a 20W power supply utilizing a TOP247Y. This power supply will be used in a cook top application where the maximum ambient temperature can reach 105C. • • • • 105C Ambient Operation TOP247Y operates at 66kHz to reduce switching losses and EMI filter size Compact PCB 7” X 3” High efficiency >85% at full load The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top 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 Output Rectification ............................................................................................. 7 4.4 Output Feedback................................................................................................. 7 5 PCB Layout ................................................................................................................ 9 6 Bill Of Materials ........................................................................................................ 10 7 Transformer Specification......................................................................................... 12 7.1 Electrical Diagram ............................................................................................. 12 7.2 Electrical Specifications..................................................................................... 12 7.3 Materials............................................................................................................ 12 7.4 Transformer Build Diagram ............................................................................... 13 7.5 Transformer Construction.................................................................................. 13 7.6 Bobbin Drawing ................................................................................................. 14 7.7 Transformer Spreadsheets................................................................................ 15 8 Performance Data .................................................................................................... 17 8.1 Efficiency........................................................................................................... 17 8.2 Minimum Load Input Power............................................................................... 17 8.3 Regulation ......................................................................................................... 18 8.3.1 Load ........................................................................................................... 18 8.3.2 Line ............................................................................................................ 18 9 Thermal Performance............................................................................................... 19 10 Waveforms............................................................................................................ 20 10.1 Drain Voltage and Current, Normal Operation .................................................. 20 10.2 Output Voltage Start-up Profile ......................................................................... 20 10.3 Drain Voltage and Current Start-up Profile........................................................ 21 10.4 Load Transient Response (75% to 100% Load Step) ....................................... 21 10.5 Output Ripple Measurements............................................................................ 22 10.5.1 Ripple Measurement Technique ................................................................ 22 10.5.2 Measurement Results ................................................................................ 23 11 Control Loop Measurements................................................................................. 24 11.1 85 VAC Input..................................................................................................... 24 11.2 265 VAC Input................................................................................................... 24 12 Conducted EMI ..................................................................................................... 25 13 Revision History.................................................................................................... 26 Page 2 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top 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 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 1 Introduction This document is an engineering prototype report describing a 20W power supply utilizing a TOP247Y. This power supply will be used in a cook top application where the maximum ambient temperature can reach 105C. 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 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top 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 Total Output Power Continuous Output Power Peak 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 12 50 1.25 0.25 -14 100 0.4 0.05 POUT 20.6 40 η 85 V mV A V mV A W W % ± 5% 20 MHz bandwidth ± 10% 20 MHz bandwidth Measured at POUT (20.6 W), 25 oC Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge TBD kV Surge TBD kV Ambient Temperature Page 5 of 27 TAMB 0 105 o C 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 3 Schematic Figure 2 – Schematic. Page 6 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 4 Circuit Description The schematic in Figure 2 shows an off-line Flyback converter using the TOP247Y. The circuit is designed for 85 VAC to 265 VAC input and provides two outputs; +12V @ 1.25A and –14V @ 0.4A. 4.1 Input EMI Filtering Capacitor C1 and the leakage inductance of L1, filter differential-mode conducted EMI. Inductor L1 acts to reduce common-mode conducted EMI. 4.2 TOPSwitch Primary The discrete full bridge rectifier bridge comprised of D1-D4 and C2 provide a high voltage DC BUS for the primary circuitry. C3 bypasses the high voltage DC rail. Resistor R1 provides damping that reduces mid-frequency conducted EMI. The DC rail is applied to the primary winding of T1. The other side of the transformer primary is driven by the integrated MOSFET in U1. Diode D6 and D5 clamp leakage spikes generated when the MOSFET in U1 switches off. Capacitor C4 reduces the operating temperature of D5 by bypassing the leading edge of the primary leakage spike away from D5. Resistor R2 provides damping to reduce drain ringing. Resistor R3 sets the low-line turn-on threshold to approximately 69 VAC, and also sets the over voltage shutdown level to approximately 320 VAC. R4 sets the U1 current limit to approximately 40% of its nominal value. This limits the output power delivered during fault conditions. C5 bypasses the U1 CONTROL pin. C6 has 3 functions. It provides the energy required by U1 during startup, sets the auto-restart frequency during fault conditions, and also acts to roll off the gain of U1 as a function of frequency. R5 adds a zero to stabilize the power supply control loop. Diode D7 and C19 provide rectified and filtered bias power for U2 and U1. 4.3 Output Rectification The output of T1 is rectified and filtered by D8, C10-C11 and D9, C14. Inductor L2 (L3), C12 (C15), and C13 (C16) provide additional high frequency filtering. Resistor R6 (R7) and C8 (C9) provide snubbing for D8 (D9). Choosing the proper snubber values is important for low zero-load power consumption and for high frequency EMI suppression. The snubber components were chosen so that the turn-on voltage spike at the D8 (D9) anode is slightly under-damped. Increasing C8 and reducing R6 will improve damping and high frequency EMI, at the cost of higher zero-load power consumption. 4.4 Output Feedback Resistors R11 and R12 divide down the supply output voltage and apply it to the reference pin of error amplifier U3. Shunt regulator U3 drives Optocoupler U2 through resistor R6 to provide feedback information to the U1 CONTROL pin. The Optocoupler output also provides power to U1 during normal operating conditions. Diode D10 and C18 apply drive to the Optocoupler during supply startup to eliminate output voltage overshoot. Diode D10 isolates C18 from the supply feedback loop after startup. Resistor R9 discharges C18 when the supply is off. Page 7 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 Components C6, C17, R5, R10 and R8 all play a role in compensating the power supply control loop. Capacitor C6 rolls off the gain of U1 at relatively low frequency. Resistor R5 provides a zero to cancel the phase shift of C6. Resistor R8 sets the gain of the direct signal path from the supply output through U2 and U3. Components C17 and R10 roll off the gain of U3 Page 8 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 5 PCB Layout Figure 3 – Printed Circuit Layout. Page 9 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 6 Bill Of Materials Item 1 QTY Part Reference 1 C1 Mfg Part Number Description Mfg Value ECQ-U2A224ML 220nF 2 1 C2 UVZ2G221MRD 220nF, 275 VAC, Film, X2 Panasonic 220uF, 450V, Electrolytic, Gen. Purpose Nichicon 3 1 C3 5GASS20 20nF, 500 V, Disc Ceramic Vishay 20nF 220uF 4 1 C4 ECK-D3A472KBN 4.7nF, 1 kV, Disc Ceramic Panasonic 4.7nF 5 4 C5 C13 C16 C17 ECU-S1H104KBB Panasonic 100nF United Chemi-Con 47uF Vishay 2.2nF NIC Components Corp 470pF United Chemi-Con 1000uF United Chemi-Con 100uF United Chemi-Con 470uF United Chemi-Con 10uF 6 1 C6 KME16VB47RM5X11LL 100nF, 50 V, Ceramic, X7R 47uF, 16 V, Electrolytic, Gen. Purpose, (5 x 11) 7 1 C7 440LD22 2.2nF, Ceramic, Y1 8 2 C8 C9 NCD471K1KVY5F 9 2 C10 C11 10 2 C12 C15 11 1 C14 12 1 C18 13 1 C19 470pF, 1 kV, Disc Ceramic 1000uF, 35 V, Electrolytic, Low ESR, 30mOhm, (12.5 x 25) LXZ35VB102MK25LL 100uF, 35 V, Electrolytic, Gen. KME35VB101M6X11LL Purpose, (8 x 11.5) 470uF, 35 V, Electrolytic, Very KZE35VB471MJ20LL Low ESR, 23mOhm, (10 x 20) 10uF, 50 V, Electrolytic, Gen. KME50VB10RM5X11LL Purpose, (5 x 11) 1uF, 50 V, Electrolytic, Gen. KMG50VB1R0M5X11LL Purpose, (5 x 11) 14 4 D1 D2 D3 D4 1N5407 15 1 D5 P6KE200A 16 1 D6 UF4005 17 2 D7 D10 1N4148 18 1 D8 MBR2060CT 19 1 D9 SB580 80 V, 5 A, Schottky, DO-201AD Vishay SB580 20 1 F1 3,701,315,041 Wickman 3.15 A 21 1 J1 26-48-1045 Molex CON4 22 1 J2 26-48-1031 Molex CON3 23 1 L1 ELF18N012A 3.15 A, 250V,Fast, TR5 CONN HEADER 4POS(1 X 4) .156 VERT TIN CONN HEADER 3POS(1 X 3) .156 VERT TIN 9.5mH, 1.2 A, Common Mode Choke Panasonic 9.5mH 24 1 L2 ELC08D3R3E 3.3uH, 5.7 A Panasonic 3.3uH 25 1 L3 822LY-3R3M 3.3uH, 2.66 A Toko 3.3uH 26 1 R1 CFR-25JB-2R2 2.2 R, 5%, 1/4 W, Carbon Film Yageo 2.2 27 1 R2 CFR-50JB-68K 68 k, 5%, 1/2 W, Carbon Film Yageo 28 1 R3 CFR-50JB-2M2 2.2 M, 5%, 1/2 W, Carbon Film Yageo 2.2 M 28 k 1% United Chemi-Con 800 V, 3 A, Rectifier, DO-201AD Vishay 200 V, 5 W, 5%, DO204AC (DO-15) Vishay 600 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 Vishay 75 V, 300mA, Fast Switching, DO-35 Vishay 60 V, 20 A, Dual Schottky, TO220AB Vishay 1uF 1N5407 P6KE200A UF4005 1N4148 MBR2060CT 68 k 29 1 R4 MFR-25FBF-13K0 13 k, 1%, 1/4 W, Metal Film Yageo 30 1 R5 CFR-12JB-6R8 6.8 R, 5%, 1/8 W, Carbon Film Yageo 6.8 31 2 R6 R7 CFR-25JB-33R 33 R, 5%, 1/4 W, Carbon Film Yageo 33 32 1 R8 CFR-12JB-470R 470 R, 5%, 1/8 W, Carbon Film Yageo 33 1 R9 CFR-12JB-15K 15 k, 5%, 1/8 W, Carbon Film Yageo 15 k 34 1 R10 CFR-12JB-3K3 3.3 k, 5%, 1/8 W, Carbon Film Yageo 3.3 k 35 1 R11 MFR-25FBF-38K3 38.3 k, 1%, 1/4 W, Metal Film Yageo 38.3 k 36 1 R12 MFR-25FBF-10K0 10 k, 1%, 1/4 W, Metal Film Yageo 10 k 37 1 R13 CFR-12JB-1K0 1 k, 5%, 1/8 W, Carbon Film Yageo 1k Page 10 of 27 470 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 38 1 RT1 CL150 NTC Thermistor, 5 Ohms, 4.7 A Thermometrics 5 ohm 39 1 RV1 V275LA20A Littlefuse 275Vac 40 1 T1 YC-3508 Ying Chin EER35 41 1 U1 TOP247Y Power Integrations TOP247Y 42 1 U2 ISP817D, PC817X4 Isocom, Sharp PC817D 43 1 U3 TL431CLP 275 V, 75 J, 14 mm, RADIAL Bobbin, EER35, Vertical, 14 pins TOPSwitch-GX, TOP247Y, TO220-7C Opto coupler, 35 V, CTR 300600%, 4-DIP 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92 Texas Instruments TL431 Page 11 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top 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 1-7 to Pins 8-14 Pins 1-4, all other windings open, measured at 66 kHz, 0.4 VRMS Pins 1-4, all other windings open Pins 1-4, with Pins 8-14 shorted, measured at 66 kHz, 0.4 VRMS 3000 VAC 683 µH, -/+10% 500 kHz (Min.) 4 µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] Description 2 Core: EER35 PC40 or equivalent, Al=124nH/T Bobbin: Yin-Ching P/N: YC-3508 14-pin Magnet Wire: #25 AWG Heavy Build Magnet Wire: #26 AWG Heavy Build Tape: 3M Tape Varnish Page 12 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 7.4 105C Dual Output Cook top Power Supply April 20, 2005 Transformer Build Diagram Figure 5 – Transformer Build Diagram. 7.5 Transformer Construction Bobbin Preparation Margin Tape ½ Primary Basic Insulation Bias Winding Basic Insulation Secondary Winding Basic Insulation Secondary Winding Shield Winding ½ Primary Outer Wrap Final Assembly Page 13 of 27 Pull Pin 9 on bobbin [2] to provide polarization. Bobbin pin-out is shown below. Apply 3 mm wide margin to both sides of bobbin using item [5]. Match height of primary and bias windings. Start at Pin 4. Wind 37 turns of #25 AWG in 1 layer, finish on Pin 3. Use one layer of tape [5] for basic insulation. Starting at Pin 6, wind 9 quadfilar turns of #25 AWG. Spread turns evenly across bobbin width. Finish on Pin 7. Use three layers of tape [5] for basic insulation. Start at Pins 10 and 11. Wind 12 trifilar turns of #25 AWG uniformly on a single layer. Finish on Pin 8. Use three layers of tape [5] for basic insulation. Start at Pins 13 and 14. Wind 10 quadfilar turns of #25 AWG uniformly on a single layer. Finish on Pins 10 and 11. Start at Pin 1. Wind 11 quadfilar turns of #26 AWG in 1 layer, finish on Pin 5. Start at Pin 3. Wind 37 turns of #25 AWG in 1 layer, finish on Pin 1. Wrap windings with 3 layers of tape [5]. Assemble and secure core halves so that the tape wrapped E core is at the bottom of the transformer. Dip varnish cores. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 7.6 105C Dual Output Cook top Power Supply April 20, 2005 Bobbin Drawing Page 14 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 7.7 105C Dual Output Cook top Power Supply April 20, 2005 Transformer Spreadsheets Page 15 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 Page 16 of 27 105C Dual Output Cook top Power Supply April 20, 2005 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 8 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 8.1 Efficiency 90.00% 89.00% 88.00% Efficiency ( η ) 87.00% 86.00% 85.00% 84.00% 83.00% Full Load (21W) 82.00% 2 X Full Load (42W) 81.00% 80.00% 50 100 150 200 250 300 Input Voltage (VAC) Figure 6 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz. 8.2 Minimum Load Input Power 5.8 5.7 Input Power (W) 5.6 5.5 5.4 5.3 5.2 5.1 5 50 100 150 200 250 300 Input Voltage (VAC) Figure 7 - Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. Page 17 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 8.3 105C Dual Output Cook top Power Supply April 20, 2005 Regulation 8.3.1 Load Regulation Tolerance (%) 120.00% 115.00% 110.00% 105.00% 100.00% +12V @ 120VAC 95.00% -14V @ 120VAC 90.00% +12V @ 240AC 85.00% -14V @ 240VAC 80.00% min loa d min +12 / ma ma x -1 x+ 12/ m 4 ma in 1 x+ 2X 12/ m 4 ax loa d -14 Load Condition Figure 8 – Load Regulation, Room Temperature. 8.3.2 Line 105.00% Regulation Tolerance (%) 104.50% 104.00% 103.50% 103.00% 102.50% +12V Output 102.00% -14V Output 101.50% 101.00% 100.50% 100.00% 50 100 150 200 250 300 Input Voltage (VAC) Figure 9 – Line Regulation, Room Temperature, Full Load. Page 18 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 9 Thermal Performance Unit was placed into a box in a thermal chamber at 105ºC and allowed to reach thermal equilibrium. The unit was placed in a box to prevent any airflow from the thermal chamber fan from reaching the unit. Thermocouples were placed on the TOPSwitch, output rectifier and transformer. At full rated load the unit does not have any appreciable temperature rise over the ambient. Temperature (ºC) Item Page 19 of 27 115VAC 230VAC Ambient 105 105 Transformer (T1) 109 105 TOPSwitch (U1) 105 105 Rectifier (D8) 105 105 Capacitor (C10) 105 105 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 10 Waveforms 10.1 Drain Voltage and Current, Normal Operation Figure 10 - 85 VAC, Full Load. Upper: IDRAIN, 0.5 A / div Lower: VDRAIN, 100 V, 5 µs / div Figure 11 - 265 VAC, Full Load Upper: IDRAIN, 0.5 A / div Lower: VDRAIN, 200 V / div, 5 µs / div 10.2 Output Voltage Start-up Profile +12VDC +12VDC -14VDC -14VDC 5V/div 5V/div Figure 12 - Start-up Profile, 85VAC 2 V, 5 ms / div. Page 20 of 27 Figure 13 - Start-up Profile, 265 VAC 2 V, 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 10.3 Drain Voltage and Current Start-up Profile Figure 14 - 85 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 100 V & 1 ms / div. Figure 15 - 265 VAC Input and Maximum Load. Upper: IDRAIN, 1 A / div. Lower: VDRAIN, 200 V & 1 ms / div. 10.4 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 16 – Transient Response, 115 VAC, 75-10075% Load Step. Top: Load Current, 200mA/div. Bottom: Output Voltage 50 mV, 500 µs / div. Page 21 of 27 Figure 17 – Transient Response, 230 VAC, 75-10075% Load Step Upper: Load Current, 200mA/ div. Bottom: Output Voltage 50 mV, 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 10.5 Output Ripple Measurements 10.5.1 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 18 and Figure 19. 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 18 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 19 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added) Page 22 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 10.5.2 Measurement Results Figure 20 – 12V Ripple, 85 VAC, Full Load. 2 ms, 20 mV / div Page 23 of 27 Figure 21 - 12V Ripple, 265 VAC, Full Load. 2 ms, 20 mV / div Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 11 Control Loop Measurements 11.1 85 VAC Input Figure 22 - Gain-Phase Plot, ½ Load (10W) Scale: Gain = 10 dB/div, Phase = 40 °/div. Crossover Frequency = 274Hz Phase Margin = 46.9° Figure 23 - Gain-Phase Plot, Full Load (20W) Scale: Gain = 10 dB/div, Phase = 40 °/div. Crossover Frequency = 403.7Hz Phase Margin = 75.9° Figure 24 - Gain-Phase Plot, 2X Load (40W) Scale: Gain = 10 dB/div, Phase = 40 °/div. Crossover Frequency = 1.75 kHz Phase Margin = 16.9° 11.2 265 VAC Input Figure 25 - Gain-Phase Plot, ½ Load (10W) Scale: Gain = 10 dB/div, Phase = 40 °/div. Crossover Frequency = 528.3Hz Phase Margin = 75.1° Figure 26 - Gain-Phase Plot, Full Load (20W) Scale: Gain = 10 dB/div, Phase = 40 °/div. Crossover Frequency = 950.4Hz Phase Margin = 52.8° Figure 27 - Gain-Phase Plot, 2X Load (40W) Scale: Gain = 10 dB/div, Phase = 40 °/div. Crossover Frequency = 1.61 kHz Phase Margin = 69.6° The power supply has very good stability criteria over the intended operating input voltage and output power range. Page 24 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 12 Conducted EMI A conducted EMI scan of the prototype was taken to determine the effectiveness of the input filter, transformer construction and layout. The following plots show the Peak performance of the converter against quasi-peak (QP) and average (AVG) limits of EN55022 Class B. Both scans were taken at 115VAC/60Hz input with peak load applied to both output rails. Figure 28 - Conducted EMI, Maximum Steady State Load (Line) Figure 29 - Conducted EMI, Maximum Steady State Load (Neutral) Since the peak scan is below the average limits, it is expected that the QP scans would have greater than 10db of margin below the limits. Page 25 of 27 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 2005 13 Revision History Date April 20, 2005 Page 26 of 27 Author EC/RSP Revision 1.0 Description & changes Reviewed Initial release VC / AM Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-53 105C Dual Output Cook top Power Supply April 20, 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. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue, San Jose, CA 95138, USA Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] GERMANY Rueckertstrasse 3, D-80336, Munich, Germany Phone: +49-895-527-3910 Fax: +49-895-527-3920 e-mail: [email protected] JAPAN Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama, 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN 17F-3, No. 510, Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. 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