Design Example Report Title 21W (45W peak) Multiple Output Power Supply using TOP246Y Input: 90 – 265 VAC Specification Output: 12V / 0.72A (2.75APK), 5V / 1.4A, 3.3V / 1.51A, 3V / 0.1A, -22V/4mA Application DVD Recorder with HDD Author Power Integrations Applications Department Document Number DER-40 Date February 22, 2005 Revision 3.0 Summary and Features • • • • • • • • • No linear regulators used One transformer solution Small 6.8 mH common mode choke, small X-cap and Y-cap EMI has 12 dB margin Good cross regulation Small heatsinks Good peak power capability (can operate down to 75 Vac) EEL25 transformer does not use triple insulated wire, or Teflon sleeving Meets low power standby requirements 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-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 Table Of Contents 1 2 3 4 5 Introduction ................................................................................................................... 4 Photograph.................................................................................................................... 4 Power Supply Specification........................................................................................... 5 Schematic ..................................................................................................................... 6 Circuit Description ......................................................................................................... 8 5.1 Input EMI Filtering .................................................................................................. 8 5.2 TOPSwitch Primary................................................................................................ 8 5.3 Outputs................................................................................................................... 8 5.4 Output Feedback.................................................................................................... 8 5.5 Rev 2 to Rev3 changes.......................................................................................... 9 6 PCB Layout ................................................................................................................. 10 7 Bill Of Materials ........................................................................................................... 11 8 Transformer Specification ........................................................................................... 13 8.1 Electrical Diagram ................................................................................................ 13 8.2 Electrical Specifications ....................................................................................... 13 8.3 Materials............................................................................................................... 14 8.4 Transformer Build Diagram .................................................................................. 14 8.4.1 WD#3 Copper Foil build diagram: ................................................................. 15 8.4.2 WDG#4 & #5 Copper Foil build diagram: ...................................................... 15 8.5 Transformer Construction..................................................................................... 16 8.6 Transformer Spreadsheets................................................................................... 17 9 Performance Data ....................................................................................................... 20 9.1 Regulation in DVD Recording Mode .................................................................... 20 9.2 Efficiency.............................................................................................................. 20 9.3 Standby Input Power............................................................................................ 21 9.4 Peak Load Margin ................................................................................................ 21 10 Thermal Performance .............................................................................................. 22 11 Control Loop Measurements.................................................................................... 23 11.1 110 VAC Maximum Continuous Load .................................................................. 23 11.2 230 VAC Maximum Continuous Load .................................................................. 23 12 Waveforms............................................................................................................... 24 12.1 Drain Voltage Normal Operation .......................................................................... 24 12.2 Output Voltage Start-up Profile ............................................................................ 24 12.3 Drain Voltage Start-up Profile............................................................................... 26 13 Conducted EMI ........................................................................................................ 27 13.1 230V High Line EMI ............................................................................................. 27 13.2 110V Low Line EMI .............................................................................................. 28 14 Revision History....................................................................................................... 29 Page 2 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built. Page 3 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 1 Introduction This document is an engineering report describing the PSU design using TOP246Y. This design adopts a one transformer solution instead of two transformers as originally used in the application, eliminates one X-cap, several Y-caps, a linear regulator and several heatsinks, and uses a smaller transformer. The new design 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. EcoSmartTM features allow low consumption during lower power standby mode. 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 3 Power Supply Specification The load currents below are actual measurements of the DVD/R unit. The capability of the PSU design is higher than the measured consumption of the unit. 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 3.465 V mV Output Current 1 IOUT1 3.3 150 1.51 A Output Voltage 2 Output Ripple Voltage 2 Output Current 2 VOUT2 VRIPPLE2 IOUT2 4.75 5.0 150 1.40 5.25 V mV A Output Voltage 3 Output Ripple Voltage 3 Output Current 3 VOUT3 VRIPPLE3 IOUT3 10.5 12 240 0.72 13.5 V mV A Output Voltage 4 (FL) Output Ripple Voltage 4 Output Current 4 VOUT4 VRIPPLE4 IOUT4 2.5 3.0 3.5 V mV A Output Voltage 5 Output Ripple Voltage 5 Output Current 5 VOUT5 VRIPPLE5 IOUT5 -19.8 -24.2 V mV A Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Safety Ambient Temperature POUT POUT_PEAK η 2.75 0.1 -22.0 280 0.004 21 45 74 20 MHz Bandwidth for all the outputs W W % Actual load measurement Measured at POUT (21W), 25 oC Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II TAMB 25 o C Free convection, sea level Note: When the maximum input power happens, only 12V output shows a significantly higher peak power. All other outputs are specified at average output current at DVD drive recorder mode. Page 5 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 4 Schematic Figure 2 – Schematic (Primary side). Page 6 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 Figure 3 –Schematic (Secondary side) Page 7 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 5 Circuit Description The schematic in Figure 2 shows an off-line flyback converter using the TOP246Y. The circuit is designed for 90 VAC to 265 VAC input. The schematic in Figure 3 shows the secondary circuit to supply the power rails to the DVD circuits, with associated power rail control for low power modes. 5.1 Input EMI Filtering Capacitors C1, C2, X-capacitor C30, and common-mode choke L1 act as an input filter to reduce common mode and differential mode EMI. The X capacitor and Common Mode choke required in this design to achieve low EMI is very small and low cost, because of the frequency ‘jitter’ (modulation) feature of the TOPSwitch-GX. 5.2 TOPSwitch Primary The AC line voltage is rectified and filtered to generate a high voltage DC bus via D1-4 and C1 and C2. Diode D5, C6, and R4, and R45 clamp leakage spikes generated when the MOSFET in 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 Q1, D7, C7, C28 R5, R6, R7, R39, R48 provide a signal to the U1 X pin to allow aggressive frequency reduction at light load, reducing power consumption. 5.3 Outputs The T1 output is rectified and filtered by Diodes D8-D12 and filtered by inductor/capacitor networks on most outputs. MOSFETs Q3, Q4 and Q5 are used to switch the low supply rails. Darlington device Q2 is used to switch the 12V rail. Level shifting transistors Q8-Q14 are used to drive the rail switch devices in response to logic signals PWR_CNTL1-4. 5.4 Output Feedback Output feedback is used from a combination of the 5 V and the 3.3 V rails. Resistors R31 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 C20 applies drive to the optocoupler during supply startup to reduce output voltage overshoot. Capacitor C21 and R29 provide frequency compensation for error amplifier U3. Page 8 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 5.5 Rev 2 to Rev3 changes OV/UV resistor from L pin was added to provide additional protection, using the TOPSwitch-GX integrated under-voltage / over-voltage feature. The X-pin frequency reduction circuit was also modified for improved margin. Add Changes Delete Page 9 of 30 RT1, RV1, R46, R38, R47, R37, R48, C28 Updated Gain/Phase plot C7 from 47nF to 470nF C21 from 10nF to 100nF R6 from 18k to 68k R7 from 16k to 3.6k R27 from 470 to 82 VR6 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 6 PCB Layout Figure 4 – Printed Circuit Layout Note: R32 is not stuffed on the PCB. Page 10 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 7 Bill Of Materials Item Qua. Value Part Ref. Description Mfg Part Number 1 2 68 uF C1 C2 68 uF, 400 V, Electrolytic, Low ESR, 530 mOhm, (18 x 25) KMX400VB68RM18X25LL Mfg United Chemi-Con 2 1 22 uF C3 22 uF, 50 V, Electrolytic, Very Low ESR, 340 mOhm, (5 x KZE50VB22RME11LL United Chemi-Con 3 2 47 uF C4 C20 4 5 100 nF C5 C17 C18 C19 C21 100 nF, 50 V, Ceramic, X7R ECU-S1H104KBB Panasonic 5 1 1 nF C6 NCD102K1KVY5F 11) 47 uF, 16 V, General Purpose, (5 x 11) 1 nF, 1 kV, Disc Ceramic Any NIC Components Corp 6 1 470 nF C7 470 nF, 50 V, Ceramic, X7R ECU-S1H474KBB Panasonic 7 2 1000 uF C8 C29 1000 uF, 25 V, Electrolytic, Very Low ESR, 21 mOhm, KZE25VB102MK20LL United Chemi-Con (12.5 x 20) 8 2 220 uF C9 C22 220 uF, 25 V, Electrolytic, Low ESR, 120 mOhm, (8 x 12) LXZ25VB221MH15LL United Chemi-Con 9 1 1500 uF C10 1500 uF, 10 V, Electrolytic, Very Low ESR, 22 mOhm, (10 KZE10VB152MJ25LL United Chemi-Con 10 1 2200 uF C11 KZE10VB222MK20LL United Chemi-Con x 25) 2200 uF, 10 V, Electrolytic, Very Low ESR, 21 mOhm, (12.5 x 20) 11 6 220 uF C12 C13 C23 C24 220 uF, 10 V, Electrolytic, Low ESR, 250 mOhm, (6.3 x LXZ10VB221MF11LL United Chemi-Con C25 C26 11.5) 12 1 56 uF C14 56 uF, 35 V, Electrolytic, Low ESR, 250 mOhm, (6.3 x 11.5) LXZ35VB56RMF11LL United Chemi-Con 13 1 100 uF C15 100 uF, 10 V, Electrolytic, Very Low ESR, 300 mOhm, (5 x KZE10VB101ME11LL United Chemi-Con 11) 14 2 100 uF C16 C27 100 uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) KME10VB101M5X11LL United Chemi-Con 15 1 390 pF C28 390 pF, 50 V, Ceramic, COG ECU-S1H391JCA Panasonic 16 1 47 nF C30 47 nF, 275 VAC, Film, X2 B81130B1473M Epcos 17 1 1 nF C31 1 nF, Ceramic, Y1 440LD10 Vishay 18 5 1N4007GP D1 D2 D3 D4 D5 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 1N4007GP Vishay 19 1 BAV20 D6 200 V, 200 mA, Fast Switching, 50 ns, DO-35 BAV20 Vishay 20 1 1N4148 D7 75 V, 300 mA, Fast Switching, DO-35 1N4148 Vishay 21 1 BYV27-200 D8 200 V, 2 A, Ultrafast Recovery, 25 ns, SOD57 BYV27-200 Philips 22 1 SB560 D9 60 V, 5 A, Schottky, DO-201AD SB560 Vishay 23 1 SB540 D10 40 V, 5 A, Schottky, DO-201AD SB540 Vishay 24 1 UF4003 D11 200 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 UF4003 Vishay 25 1 UF4001 D12 50 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 UF4001 Vishay 26 3 1N4001 D13 D16 D17 50 V, 1 A, Rectifier, DO-41 1N4001 Vishay 27 2 1N5817 D14 D15 20 V, 1 A, Schottky, DO-41 1N5817 Vishay 28 1 2A F1 2 A,250V, Slow, TR5 3,721,200,041 Wickman 29 1 CON3 J1 3 Position (1 x 3) header, 0.156 pitch, Vertical 26-48-1031 Molex 30 4 DVD/RW J2 J3 J4 J5 4 Position (1 x 4) header, 0.1 pitch, Vertical 22-28-4049 Molex 31 1 P/Ctrl J6 5 Position (1 x 5) header, 0.1 pitch, Vertical 22-28-4050 Molex 32 1 PS1 J7 10 Position (1 x 10) header, 0.1 pitch, Vertical 22-28-4100 Molex 33 1 PS2 J8 8 Position (1 x 8) header, 0.1 pitch, Vertical 22-28-4080 Molex 34 1 6.8 mH L1 6.8 mH, 0.8 A, Common Mode Choke ELF15N008 Panasonic 35 3 3.3 uH L2 L3 L4 3.3 uH, 2.66 A 822LY-3R3M Toko 36 4 Mounting holes M1 M2 M3 M4 PCB Terminal Hole, 18 AWG N/A N/A 37 4 2N3906 Q1 Q12 Q13 Q14 PNP, Small Signal BJT, 40 V, 0.2 A, TO-92 2N3906 Fairchild 38 1 TIP105 Q2 PNP Darlington, Power BJT, 60 V, 8 A, TO-220 TIP105 Fairchild 39 4 SI2306DS Q3 Q4 Q5 Q6 20 V, N-Channel, SOT 23 SI2306ADS Vishay 40 1 MPS6601 Q7 NPN, Small Signal BJT, TO-92 MPS6601 On Semiconductor 41 4 2N3904 Q8 Q9 Q10 Q11 NPN, Small Signal BJT, 40 V, 0.2 A, TO-92 2N3904 Fairchild 42 1 200 k R4 200 k, 5%, 1/2 W, Carbon Film CFR-50JB-200K Yageo Page 11 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 43 1 240 R5 240 R, 5%, 1/8 W, Carbon Film CFR-12JB-240R Yageo 44 1 68 k R6 68 k, 5%, 1/8 W, Carbon Film CFR-12JB-68K Yageo 45 1 3.6 k R7 3.6 k, 5%, 1/4 W, Carbon Film CFR-25JB-3K6 Yageo 46 1 6.8 R8 6.8 R, 5%, 1/8 W, Carbon Film CFR-12JB-6R8 Yageo 47 1 11.8 k R9 11.8 k, 1%, 1/4 W, Metal Film MFR-25FBF-11K8 Yageo 48 1 68 R10 68 R, 5%, 1/4 W, Carbon Film CFR-25JB-68R Yageo 49 5 4.7 k R11 R14 R20 R21 4.7 k, 5%, 1/8 W, Carbon Film CFR-12JB-4K7 Yageo 20 k, 5%, 1/8 W, Carbon Film CFR-12JB-20K Yageo R23 50 7 20 k R12 R13 R18 R22 R26 R29 R34 51 2 510 k R15 R17 510 k, 5%, 1/4 W, Carbon Film CFR-25JB-510K Yageo 52 1 510 k R16 510 k, 5%, 1/8 W, Carbon Film CFR-12JB-510K Yageo 53 1 100 k R19 100 k, 5%, 1/8 W, Carbon Film CFR-12JB-100K Yageo 54 3 47 k R24 R25 R35 47 k, 5%, 1/8 W, Carbon Film CFR-12JB-47K Yageo 55 1 82 R27 82 R, 5%, 1/4 W, Carbon Film CFR-25JB-82R Yageo 56 2 10 k R28 R39 10 k, 5%, 1/8 W, Carbon Film CFR-12JB-10K Yageo 57 1 10 k R30 10 k, 1%, 1/4 W, Metal Film MFR-25FBF-10K0 Yageo 58 1 16.5 k R31 16.5 k, 1%, 1/4 W, Metal Film MFR-25FBF-16K5 Yageo 59 1 37.4 k R32 37.4 k, 1%, 1/4 W, Metal Film MFR-25FBF-37K4 Yageo 60 1 22 k R33 22 k, 5%, 1/4 W, Carbon Film CFR-25JB-22K Yageo 61 1 1 R36 1 R, 5%, 1/4 W, Carbon Film CFR-25JB-1R0 Yageo 62 1 1k R37 1 k, 5%, 1/4 W, Carbon Film CFR-25JB-1K0 Yageo 63 3 1M R38 R46 R47 1 M, 5%, 1/4 W, Carbon Film CFR-25JB-1M0 Yageo 64 3 22 k R40 R43 R44 22 k, 5%, 1/8 W, Carbon Film CFR-12JB-22K Yageo 65 2 4.7 M R41 R42 4.7 M, 5%, 1/8 W, Carbon Film CFR-12JB-4M7 Yageo 66 1 30 R45 30 R, 5%, 1/2 W, Carbon Film CFR-50JB-30R Yageo 67 1 30 k R48 30 k, 5%, 1/4 W, Carbon Film CFR-25JB-30K Yageo 68 1 16 RT1 NTC Thermistor, 16 Ohms, 1.7 A CL180 Thermometrics 69 1 320 Vac RV1 320 V, 26 J, 7 mm, RADIAL V320LA7 Littlefuse 70 1 EEL25 T1 Custom 71 1 TOP246Y U1 TOPSwitch-GX, TOP246Y, TO220-7C TOP246Y Power Integrations 72 1 PC817D U2 Opto coupler, 35 V, CTR 80-160%, 4-DIP ISP817A, PC817X1 Isocom, Sharp 73 1 LMV431_A U3 1.24V Shunt Reg IC LMV431ACZ National Semiconductor 74 1 1N4737A VR1 7.5 V, 5%, 1 W, DO-41 1N4737A 75 1 1N5229B VR2 4.3 V, 5%, 500 mW, DO-35 1N5229B Diodes Inc. Microsemi 76 1 1N5251B VR3 22 V, 5%, 500 mW, DO-35 1N5251B Microsemi 77 1 1N5239B VR4 9.1 V, 5%, 500 mW, DO-35 1N5239B Microsemi 78 1 P6KE200A VR5 200 V, 5 W, 5%, DO204AC (DO-15) P6KE200A Vishay 79 1 H1 Heatsink Any Note: Item 79, H1 heatsink, is a plain sheet metal heatsink 11x24x0.5 mm with a solderable tab at one end. It is soldered onto cathode of D9, which is an axial diode. Material used on the prototype was copper but plated mild steel can be used. Page 12 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 8 Transformer Specification 8.1 Electrical Diagram 1 WD#1 Cancellation 14 15T #30 x 2 WD#6 12V O/P 4T # 30 x 2 NC First Half Primary 13 3 WD#2 1T CU Foil 28T #29 2 11 WD#3 Shield 1T CU Foil 2T CU Foil 1 WD#9 Bias & Cancellation 12 6 12T # 29 x 2 Cancellation WD#4 3.3V O/P WD#8 -22V O/P 10 8T #30 x 2 9 1 WD#11 Second Half Primary 5V O/P 7T #30 x 2 7 WD#10 WD#5 WD#7 2T # 30 28T #29 3 3V FL O/P 8 Figure 5 –Transformer Electrical Diagram 8.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance Page 13 of 30 1 second, 60 Hz, from Pins 1 - 7 to Pins 8 -14 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 7-14 shorted, measured at 132 kHz, 0.4 VRMS 3000 VAC 422 uH, -10/+10% 1M kHz (Min.) 10 µH (Max.) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 8.3 February 22, 2005 Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] 8.4 DVD/RW HDD PSU using TOP246Y Description Core: PC40EEL25, TDK or equivalent Gapped for AL of 134 nH/T2 Bobbin: EEL25, Horizontal 14 pins Magnet Wire: #30 AWG Magnet Wire: #29 AWG Magnet Wire: #28 AWG WD#3, CU Foil: 2mil x 10mm wide x 50 mm long WD#4&5 CU Foil: 2mil x 9mm wide x 134 mm long Tape: Margin 6 mm Tape: 3M 1298 Polyester Film, 10.6mm wide Tape: 3M 1298 Polyester Film, 22.4mm wide Transformer Build Diagram 1 WD#11 Second Half Primary 3 7 WD#9 & WD#10 Bias & Cancellation 6 10 WD#8 –22V O/P 12 8 WD#7 3V FL O/P 9 13 WD#6 12V O/P 14 WD#4 & WD#5 3.3V & 5V O/P 13 11 12 WD#3 Shield 1 3 WD#2 First Half Primary 2 WD#1 Cancellation 1 Figure 6 – Transformer Build Diagram. Page 14 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 8.4.1 WD#3 Copper Foil build diagram: Cu Foil 1mil; 10mm W x 46mm L 1-layer tape folded 44mm 28 AWG Figure 7 – Copper Foil Build Diagram. 8.4.2 WDG#4 & #5 Copper Foil build diagram: Cu Foil 1mil; 9mm W x 134mm 1-layer tape folded 45mm 28 AWG X 2 86mm 28 AWG X 2 28 AWG X 4 Start from this end, reverse wind Figure 8 – Copper Foil Build Diagram Page 15 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 8.5 DVD/RW HDD PSU using TOP246Y February 22, 2005 Transformer Construction Bobbin Preparation 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 Insulation WD #8 Insulation WD #9 & WD10 Insulation WD #11 Insulation Finish Page 16 of 30 Pin1 side of the bobbin orients to the left hand side. Wind item [8] at the each pin side of the bobbin to match the height of the first half primary windings. Start on Pin 1, wind 15 turns bifilar of item [3] from left to right. Wind with th tight tension. Cut the wires after finishing 15 turns. Overall, total 15 turns winding should be well fit the entire length of the bobbin. 2 Layers of tape [9] for insulation Start on pin 2, wind 28 turns of item [4] from left to right. After finishing the 28th 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 [9] for insulation. Start at Pin 1, wind 1turns of item [6]. Clock-wise wind with tension. Apply a small piece tape to secure the end of the foil. 3 Layers of tape [10] for insulation. Wind item [8] at the each pin side of the bobbin to match the height of the secondary windings. Start at pin 12, anti-clock-wise wind 2 turns of item [7]. Wind with tight. Finish the middle termination to pin 11, then continue to wind the last turn and finish it on pin 13. Apply a piece of tape to secure the end of the foil 1 Layer of tape [9] for insulation. Start at pin 14, wind 4 turns bifilar 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 13. Start at pin 9, wind 2 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 8. 1 Layer of tape [9] for insulation. Start at pin 12, wind 12 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 10. 3 Layers of tape [10] for insulation. Start on Pin 6, wind 7 turns bifilar of item [3] from left to right. Wind with th tight tension. After finishing 7 turn, bring the wire back and finish it on Pin 7. Start from the Pin 7, rout the same wires to the ending position of the previous winding, continuous to wind another 8 turns, cut the wires th after finishing 8 turns. Overall, total 15 turns winding should be well fit the entire length of the bobbin. 1Layer of tape [9] for insulation. Start on pin 3, wind 28 turns of item [4] from left to right. After finishing the th 28 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 [10] for insulation. Grind the core to get 422uH. Secure the core with tape. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 8.6 DVD/RW HDD PSU using TOP246Y February 22, 2005 Transformer Spreadsheets ACDC_TOPSwitchGX_032204; Rev.1.9; INPUT INFO INFO OUTPUT OUTPUT UNIT Copyright Power Integrations Inc. 2004 TOP_GX_FX_032204.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer ENTER APPLICATION VARIABLES VACMIN 90 Volts Minimum AC Input Voltage VACMAX 265 Volts Maximum AC Input Voltage 50 Hertz AC Mains Frequency VO 5 Volts Output Voltage PO 45 Watts Output Power fL n 0.73 Z 0.5 VB 15 tC Efficiency Estimate Loss Allocation Factor Volts 3 CIN Bias Voltage mSeconds Bridge Rectifier Conduction Time Estimate 136 uFarads Input Filter Capacitor Universal 115 Doubled/230V 90W 125W ENTER TOPSWITCH-GX VARIABLES TOP-GX TOP246 Chosen Device TOP246 TOP246 Power Power Out KI Out 0.7 External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) 1.701 1.701 Amps Use 1% resistor in setting external ILIMIT 2.079 2.079 Amps Use 1% resistor in setting external ILIMIT fS 132000 132000 Hertz fSmin 124000 124000 Hertz fSmax 140000 140000 Hertz ILIMITMIN ILIMITMAX Frequency (F)=132kHz, (H)=66kHz F Full (F) frequency option - 132kHz TOPSwitch-GX Switching Frequency: Choose between 132 kHz and 66 kHz VOR TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX Maximum Switching Frequency 103 Volts Reflected Output Voltage VDS 10 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 0.55 Ripple to Peak Current Ratio (0.4 < KRP < 1.0 : 1.0< KDP<6.0) ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type eel25 Core EEL25 Bobbin EEL25_BOBBIN EEL25 EEL25_BOBBIN P/N: PC40EE25.4/32/6.4-Z P/N: * AE 0.404 0.404 cm^2 LE 7.34 7.34 cm Core Effective Path Length AL 1420 1420 nH/T^2 Ungapped Core Effective Inductance BW 22.3 22.3 mm mm Core Effective Cross Sectional Area Bobbin Physical Winding Width M 6 Safety Margin Width (Half the Primary to Secondary L 2 Number of Primary Layers NS 3 Number of Secondary Turns Creepage Distance) DC INPUT VOLTAGE PARAMETERS VMIN Page 17 of 30 99 99 Volts Minimum DC Input Voltage Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y VMAX February 22, 2005 375 375 Volts Maximum DC Input Voltage DMAX 0.54 0.54 Maximum Duty Cycle IAVG 0.62 0.62 Amps Average Primary Current IP 1.60 1.60 Amps Peak Primary Current IR 0.88 0.88 Amps Primary Ripple Current IRMS 0.87 0.87 Amps Primary RMS Current LP 422 422 uHenries Primary Inductance NP 56 56 NB 9 9 CURRENT WAVEFORM SHAPE PARAMETERS TRANSFORMER PRIMARY DESIGN PARAMETERS ALG Primary Winding Number of Turns Bias Winding Number of Turns 134 134 nH/T^2 BM 2972 2972 Gauss Maximum Flux Density at PO, VMIN (BM<3000) BP 3864 3864 Gauss Peak Flux Density (BP<4200) 817 817 Gauss BAC Gapped Core Effective Inductance AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) ur 2053 2053 Relative Permeability of Ungapped Core LG 0.34 0.34 mm Gap Length (Lg > 0.1 mm) BWE 20.6 20.6 mm Effective Bobbin Width OD 0.37 0.37 mm Maximum Primary Wire Diameter including insulation INS 0.06 0.06 mm Estimated Total Insulation Thickness (= 2 * film DIA 0.31 0.31 mm thickness) AWG Bare conductor diameter 29 29 AWG Primary Wire Gauge (Rounded to next smaller 128 128 Cmils 147 147 Cmils/Amp !!!!!!!!!! INCREASE CMA>200 (increase L(primary standard AWG value) CM CMA Warning Warning Bare conductor effective area in circular mils layers),decrease NS,larger Core) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 29.94 29.94 Amps Peak Secondary Current ISRMS 15.14 15.14 Amps Secondary RMS Current 9.00 9.00 Amps IRIPPLE 12.18 12.18 Amps Output Capacitor RMS Ripple Current CMS 3028 3028 Cmils Secondary Bare Conductor minimum circular mils 15 15 AWG IO AWGS Power Supply Output Current Secondary Wire Gauge (Rounded up to next larger standard AWG value) DIAS 1.45 1.45 mm Secondary Minimum Bare Conductor Diameter ODS 3.43 3.43 mm Secondary Maximum Outside Diameter for Triple INSS 0.99 0.99 mm Maximum Secondary Insulation Wall Thickness 611 611 Volts Maximum Drain Voltage Estimate (Includes Effect of PIVS 25 25 Volts Output Rectifier Maximum Peak Inverse Voltage PIVB 72 72 Volts Bias Rectifier Maximum Peak Inverse Voltage Insulated Wire VOLTAGE STRESS PARAMETERS VDRAIN Leakage Inductance) TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 IO1 PO1 Page 18 of 30 3.3 1.500 4.95 Volts Output Voltage Amps Output DC Current 4.95 Watts Output Power Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 VD1 DVD/RW HDD PSU using TOP246Y 0.5 NS1 Volts 2.07 ISRMS1 IRIPPLE1 2.07 February 22, 2005 Output Diode Forward Voltage Drop Output Winding Number of Turns 2.524 2.524 Amps 2.03 2.03 Amps PIVS1 17 17 Volts CMS1 505 505 Cmils 23 23 AWG Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils AWGS1 Wire Gauge (Rounded up to next larger standard AWG value) DIAS1 0.58 0.58 mm Minimum Bare Conductor Diameter ODS1 4.97 4.97 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 0.7 NS2 Volts 6.93 ISRMS2 IRIPPLE2 6.93 Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns 1.178 1.178 Amps 0.95 0.95 Amps PIVS2 58 58 Volts CMS2 236 236 Cmils 26 26 AWG Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils AWGS2 Wire Gauge (Rounded up to next larger standard AWG value) DIAS2 0.41 0.41 mm Minimum Bare Conductor Diameter ODS2 1.49 1.49 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 0.168 0.168 Amps Output Winding RMS Current IRIPPLE3 0.14 0.14 Amps Output Capacitor RMS Ripple Current PIVS3 105 105 Volts Output Rectifier Maximum Peak Inverse Voltage CMS3 34 34 Cmils AWGS3 34 34 AWG Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) DIAS3 0.16 0.16 mm Minimum Bare Conductor Diameter ODS3 0.83 0.83 mm Maximum Outside Diameter for Triple Insulated Wire Page 19 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency. Some tests were performed using E-loads, some were performed in the actual DVD Recorder unit. The actual unit was only tested in HDD -> DVD-R recording mode, which shows the highest average and peak power draw. The DVD Recorder unit is a prototype which does not have the correct standby mode, nor the firmware to drive the control signals 1-4. So testing in the unit was done with signals 1-4 connected to 5Vsb to turn on all the switched outputs. 9.1 Regulation in DVD Recording Mode A Fluke 87 in min/max recording mode was used to capture the min and max of each output. The test was done at room temperature, 90 Vac and 265 Vac input. Output 3.3 VSB 3.3 VSW1 3.3 VSW2 5 VSB 5 VSW1 5VSW3 12 VSB 12 VSW1 3 VFL - 22V 9.2 90V (V) 3.261 3.206 3.221 5.06 4.95 5.03 11.51 12.08 2.55 - 23.3 265V (V) 3.263 3.207 3.222 5.05 4.94 5.02 11.49 12.05 2.49 -22.6 Efficiency E-loads were used for this measurement. Output 3.3 VSW1 5 VSW1 12 VSW1 3 VFL - 22V Total output Power Page 20 of 30 Load Output (V) Output ( A ) 3.22 1.53 4.95 1.39 12.01 0.87 2.53 0.1 - 23 0.004 O/P Power (W) 4.927 6.881 10.45 0.253 0.092 22.60 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y Input Voltage 90Vac 265Vac 9.3 February 22, 2005 Efficiency 76.4% 78.2% Standby Input Power With E-load at 1W condition, 12VSB @ 2.5mA, 5VSB @20mA, Power Block 2 is loaded @340mW. Input Voltage 110 Vac 230 Vac Input Power 836mW 860mW 9.4 Peak Load Margin A Flyback power supply has lowest peak power capability at minimum AC voltage. The DVD/R unit has very fluctuating power requirements, which are difficult to characterize. It draws maximum power when switching signal inputs or inserting the DVD tray. A good test for peak power margin is to see the minimum AC voltage that the unit can operate normally. The unit is powered up at, and operated at a reduced AC input voltage. The unit is cycled through different modes of operation – startup, eject, load, play, record, etc. The DVD/RW HDD functions normally. Input voltage 75Vac Result PASS 75 Vac is a very good result and implies there is plenty of margin for peak power capability. Page 21 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 10 Thermal Performance Test Condition: The DVD/RW HDD was set on the bench. The unit is recording (highest continuous load) during the test. Temperature (°C) Item 90Vac 265Vac (°C) 25 Ambient (°C) TOP246Y (U1) 67.7 56.2 5 V filter Cap (C10) 56.2 55.5 3.3 V Rectifier (D10) 75.1 74.3 5 V Rectifier (D9) 83.2 82.6 Note: H1 heatsink is attached to D9. Page 22 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 11 Control Loop Measurements The power supply is loaded at 21W continuous load. 11.1 110 VAC Maximum Continuous Load Figure 9 - Gain-Phase Plot, 110 VAC, 21W Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30°/div. Crossover Frequency = 3 kHz Phase Margin = 105° 11.2 230 VAC Maximum Continuous Load Figure 10 - Gain-Phase Plot, 230 VAC, 21W Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30°/div. Crossover Frequency = 6.5 kHz, Phase Margin = 60° Page 23 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 12 Waveforms Waveforms were taken at 25oC 12.1 Drain Voltage Normal Operation Figure 11 - 265 VAC, VDRAIN, 100 V, 5 µs / div 12.2 Output Voltage Start-up Profile 12V 12V 5V 5V Figure 12 – Start-up Profile, 90 VAC 2V/div for 5V, 5V/div for 12V, 100 ms / div. Page 24 of 30 Figure 13 – Start-up Profile, 265 VAC 2V/div for 5V, 5V/div for 12V, 100 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y -22V -22V 3.3V 3.3V Figure 14 – Start-up Profile, 90 VAC 1V/div for 3.3V, 10V/div for -22V, 200 ms / div. 5V Figure 16 – Start-up Profile, 90 VAC 1V/div for 3V FL, 500 ms / div. Page 25 of 30 February 22, 2005 Figure 15 – Start-up Profile, 265 VAC 1V/div for 3.3V, 10V/div for -22V, 200 ms / div. 5V Figure 17 – Start-up Profile, 265 VAC 1V/div for 3V FL, 500 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 12.3 Drain Voltage Start-up Profile Figure 18 - 90 VAC Input. VDRAIN, 100 V & 10 ms / div. Page 26 of 30 Figure 19 - 265 VAC Input. VDRAIN, 100 V & 20 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 13 Conducted EMI EMI was tested at room temperature and at 110 VAC & 230 VAC input. The TOP246Y PSU was installed in the DVD/RW HDD Recorder. The DVD/RW HDD was in recording mode during the test. Two conditions were tested. (1) Chassis connected to LISN ground (worst case), and (2) with no connection. Red line is QP, Blue line is AVG. EMI is low in spite of low-cost EMI filter because of TOP246Y built-in frequency jittering and E-ShieldTM transformer winding technique. 13.1 230V High Line EMI Figure 20 - Line, Secondary Grounded Figure 21 - Neutral, Secondary Grounded Figure 22 - Line, Secondary Floating Figure 23 - Neutral, Secondary Floating Page 27 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 13.2 110V Low Line EMI Figure 24 - Line, Secondary Grounded Figure 25 - Neutral, Secondary Grounded Figure 26 - Line, Secondary Floating Figure 27 - Neutral, Secondary Floating Page 28 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 2005 14 Revision History Date Sept 21, 2004 Sept 29, 2004 Author DZ DZ Revision 1.0 2.0 Feb 18, 2005 DZ 3.0 Page 29 of 30 Description & changes Initial release R1, R2, R3, R38 removed; R27 changed from 56 ohms to 470 ohms; C7 changed from 220 nF to 47 nF; R27 changed from 56 ohms to 470 ohms; small heatsink H1 is added and attached to axial diode D9; C30 is stuffed. Add OV/UV resistor; improve frequency reduction circuit, Reviewed VC / AM VC / AM AM / VC Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-40 DVD/RW HDD PSU using TOP246Y February 22, 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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