IRISMPS5 IRISMPS5 DEMO BOARD USER GUIDE INTRODUCTION : SPECIFICATION DATA 1. AC Input: V=90~265V, f=50-60Hz, The IRISMPS5 is an open frame 90W Flyback power supply unit (psu) using the IRIS4015 Integrated switcher. This demo board aims to show the capability of the IRIS4015 to handle the upper level of flyback topology power range, without the strict standby power requirement. It works with the wide range of input AC voltage (universal) and has a single output of +15V / 6amp. Switching frequency varies according to line and load condition. It operates in quasiresonant mode ( switching current is in critically discontinuous mode) at rated capacity. This switching technique enables the internal power mosfet of IRIS4015 to switch at variable frequency with minimum switching loss. Iinac= 2.2 Arms max 2. Efficiency: Typical 83% @230Vac measured at max. load 6 Amp (90W) 3. Switching Frequency: 40-390kHz 4. Vout : +15V nominal (14.55 – 15.45) 5. Iout : 0 - 6Amax 6. Ripple & Noise :<450mVpp 7. Hold-Up Time: 20msec (230Vin Full load) / 10ms (115Vin Full load) 8. Output Risetime: 15ms max @ 115Vac 9. Short Circuit Protection: Yes 10. Overvoltage Protection : Yes INPUT / OUTPUT CONNECTIONS Input : CON1 : 3-PIN CONNECTOR (MIDDLE PIN IS VOID [pin 2]) Pin 1 & 3 : AC Voltage ( 90 – 265, 50-60Hz) Output : CON2 : 4–PIN CONNECTOR Pin 1 – 2 : ++ Positive 15V Pin 3 - 4 : - - Negative www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 1 of 11 IRISMPS5 CONNECTION DIAGRAM CON1 Pin 1 & 3 (MIDDLE PIN-2 VOID) ++ Input from AC Power source -- Pin 1-2 Pin 3-4 CON2 DC Output Load 0 – 6Amp (Pin) Power Meter Ripple&Noise DMM V Oscilloscope (20MHz BW) + +Iin -Iin -Vin +Vin Sense AC1 AC Prog Source or Variac (0 – 265Vac) AC2 (V out) - + (Con1) L (Con2) + - + E-Load IRISMPS5 (+15V x 6Amp ) N - - Figure 1 : Recommended test setup www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 2 of 11 IRISMPS5 PHYSICAL LAYOUT The board layout of the IRISMPS5 Demo board is shown in Figure 2. The PCB is a double–sided FR4 type ( 2oz. copper thickness). The input of the primary section is consist of the AC input connector, fuse and EMI filter section which are located at the right side of the board, arranged in a straight forward direction. Most parts of the primary section ( high voltage area ) are surrounded by the primary heat sink to which the IRIS4015 integrated switcher is attached with insulation pad. Primary section also includes the bridge rectifier DB1 and primary bulk cap/s (C5 or C5A//C5B) and primary side and bias winding of the power transformer. The major parts in the secondary section are the DC output connector, pi-filter, precision reference voltage IC U2, secondary heat sink to which the output rectifier is attached with thermal grease. The output connector is at the leftmost part of the board. The output is filtered using a pi-filter consist of low impedance e-caps C13A - C ,inductor L3 and e-cap C15. A ceramic capacitor C16 is located at the backside of the board. This c-cap is positioned nearest at output connector pads to minimize switching noise. Figure 2. – Component layer of IRISMPS5 demo board with physical boundary and dimensions. www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 3 of 11 IRISMPS5 SCHEMATIC DIAGRAM www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 4 of 11 IRISMPS5 BILL OF MATERIALS Item Qty 1 1 Reference 2 2 3 4 5 1 R8 22R Carbon Film Resistor 5% 1/4W BCW4J220JA00 ROYAL OHM 6 1 R9 150R 1206 SMD Resistor 1% RCT06151FTP RALEC 7 1 R10 5.1k 1206 SMD Resistor 1% RCT06512FTP RALEC 0R15 1206 SMD Resistor 5% SR733ALTER15J KOA R1 Part value Description Manufacturer PN B57235S100M Supplier 10R NTC Thermistor 10ohm 3Amp EPCOS R1 alternate 10R NTC Thermistor 10ohm 4Amp MSP104M MEGATOR R2,R3 390k 1206 SMD Resistor 5% HJW4J0394T50 ROYAL OHM 2 R4,R5 390k 1206 SMD Resistor 5% HJW4J0394T50 ROYAL OHM 1 R6 47K Metal Oxide Film Resistor 5% 2W BO2SJ0473A80 ROYAL OHM 8 1 R12 9 1 R13 10 1 R11 390R 1206 SMD Resistor 1% RCT06391FTP RALEC 11 1 R14 430R 1206 SMD Resistor 1% RCT06431FTP RALEC 12 1 R15 1k 1206 SMD Resistor 1% RCT06102FTP RALEC 13 1 R16 10k 1206 SMD Resistor 1% RCT06103FTP RALEC 14 1 R17 2k 1206 SMD Resistor 1% RCT06202FTP RALEC 15 1 100k 1206 SMD Resistor 1% 16 0 R17A C1, C2 Alternate 330 nF 275VAC X2 EMI cap RCT06104FTP RALEC KNB1560 0.33UF 10% 275 ISKRA L30 R15 17 2 C1, C2 330 nF 275VAC X2 EMI cap PHE840MB6330MB14R17 EVOX RIFA 18 3 C3, C4, C12 1n5 250VAC Y1 ceramic disc capacitor KNB2520 1N5 M 250V 19 2 C5A, C5B *C5 alternate 150uF 400V AluminumE-cap AXW (DxL, 18x40) 400AXW150M 18X40 RUBYCON 330 uF 400V E-cap MXR 35mmx35mm 400MXR330MD35 RUBYCON 21 1 *C6 1nF 500V Ceramic disc cap PANOVERSEAS 22 1 C7 4n7 2kV Ceramic disc cap XC7152KH DE1105E472Z2K-SS or DEBF33D472ZN2A MURATA 23 1 C8 330pF 1206 50V ceramic capacitor C1206KRX7R9BB331 PHYCOMP 24 1 C9 22uF 35V Electrolytic Capacitor TC04RKMF35VB22MF50 NCC 20 *unstuffed ( 1206 SMD Resistor 5% ) ISKRA 25 1 C10 470pF 1kV Ceramic Disc Capacitor DEBB33A471KP2A MURATA 26 1 330pF 1206 50V ceramic capacitor C1206KRX7R9BB331 PHYCOMP 27 3 C11 C13A,C13B, C13C 1000uF 25V Low impedance e-cap ZL 25ZL1000MG4 12.5X25 RUBYCON 28 1 C14 10 nF 1206 50V ceramic capacitor C1206KRX7R9BB103 PHYCOMP 29 1 C15 1000uF 25V Low impedance e-cap YXG 25YXG1000MG4 10X28 RUBYCON 30 1 C16 100nF 1206 50V ceramic capacitor C1206KRX7R9BB104 PHYCOMP 31 1 L1 5mH Common Mode Choke UU16 Line Filter PG0201-3 Rev 2 Pulse Eng'g. 32 1 L2 bead Leaded ferrite bead ( DxL : 3.5x 5mm) RH035050ST-B CHILISIN 33 1 L3 0.76 uH 6.5 turn 8A rod coil Inductor PG0203 Pulse Eng'g. 34 1 DB1 4GBL08 4amp 800V Bridge rectifier diode 4GBL08 IR 35 1 D1 IN5407 3A, 600V Fast Recovery Rectifier IN5407 PHILIPS 36 2 D2,D4 L4148 500mW Silicon Epitaxial Diode, SMD L4148 PHILIPS 37 1 D3 11DQ03 1.1A 30V Schottky Rectifier 11DQ03 IR 38 1 D5 16CTQ100 IR 16CTQ100 16A, 100V Schottky Rectifier www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 5 of 11 IRISMPS5 39 1 F1 3.15A 40 1 T1 PQ2625 unstuffed T1 alternate Pulse Eng'g. Pulse Eng'g. WICKMAN Power Transformer 90W ER28L 268uH #unstuffed 41 1 U1 IRIS4015 Integrated Switcher IRIS4015 IR 42 1 U2 H11A817 Optocoupler H11A817B.SD QT ELEC 43 1 U3 TL431 1 45 1 46 1 47 1 CON1 2-Sided IRISMPS5 PCB FR4 2oz 3way -2 Straight square pin connector (middle pin void) 48 1 CON2 4way - 4 Straight square pin connector TL431CLP See Mechanical drawing DOC PN 1950-0601 See Mechanical drawingDOC PN 1950-0601 See PCB specs PN :19500701 PN: 5417 or List No. : 39-263030 PN: 5417 or List No. : 39-263040 ON SEMI 44 Precision Shunt Regulator Primary Heatsink ( 1.2mm thickness Copper ) Secondary Heatsink ( 1.2mm thickness Copper ) 49 1 J1 Jumper wire 0.7 diameter, 17 mm 50 1 J2 Jumper wire 0.7 diameter, 19 mm 51 1 J3 Jumper wire 0.7 diameter, 11mm 52 2 for U1, D5 SCREW Countersunk M3X10 P=.5 53 2 for U1, D5 WASHER-SPRING M3 54 2 for U1, D5 WASHER PL M2.5 OD=6.5 55 2 for U1, D5 HEX NUT M3X0.5X1.8 CS/NP 56 2 for U1, D5 Plastic bushing TO-220 4mm length 57 1 for U1 58 ER28L Fast Acting TR5 Sub-Miniature Fuse 250V TR5-F NO.19370(4A) Power Transformer 90W PQ2625 268uH Ingrid A1 Rev3 PG0202-1 Rev3 Inhouse Inhouse Molex or equivalent Molex or equivalent INSUL-W/D=3.6 13X19 Thermal grease for D5 www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 6 of 11 IRISMPS5 TEST DATA (SAMPLE WAVEFORMS) Ch1: 90Vac/50Hz, Ch2:Vout Risetime : 18.2msec Ch3 (5Amp/V) : Iout = 6Amp Ch1 : 90Vac / 50Hz, Ch2 : Vout Ch3 (5Amp/V) : Iout = 6Amp Startup delay : 1.15 sec Ch1:115Vac /50Hz, Ch2:Vout Risetime : 13.9 msec Ch3 (5Amp/V) : Iout = 6Amp Ch1 : 115Vac / 50Hz, Ch2 : Vout Ch3 (5Amp/V) : Iout = 6Amp , Startup delay : 1.1 sec Ch1 : 230Vac / 50Hz, Ch2 : Vout, Ch3 (5Amp/V) : Iout = 6Amp), Risetime : 7.97 msec Ch1 : 90Vac / 50Hz, Iout = 6Amp (90W) Ch2 : Vout , Holduptime : 12.5msec www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 7 of 11 IRISMPS5 Ch1 : 90Vac / 50Hz, Ch3 (5Amp/V) : Iout = 6Amp Ch2 : Output Ripple & Noise = 173 mVpp Ch1 : 230Vac / 50Hz, Ch3 (5Amp/V) : Iout = 6Amp Ch2 : Output Ripple & Noise = 166mVpp Ch1 : 90Vac / 50Hz, Ch3 (5Amp/V) : Iout = 6Amp Ch2 : Output Switching Noise = 173mVpp 90Vacin, Ch1 : Vds, Ch3 (5A/V) : I out = 6A Ch4 (1A / V) : Drain current, Fsw : 43kHz Ch1 : 115Vac / 50Hz, Ch3 (5Amp/V) : Iout = 6Amp Ch2 : Output Ripple & Noise = 169mVpp Ch1 : 90Vac input , Ch3 (5Amp/V): Iout = 3A Ch4 (1Amp/V) : Drain current www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 8 of 11 IRISMPS5 90Vin @90W , Ch1 : Vds, Ch2 ( 10Amp/div) : Idrain 265Vin @90W , Ch1 : Vds, Ch2 ( 10Amp/div) : Idrain @90Vac input ,Iout = 6A , Fsw ~ 43kHz Ch1 : Vds, Ch2 : VFB, Ch3 : Vrsense ( Rsense = 0R15) Ch4 (5Amp/V) : Output rectifier current @265Vac input ,Iout = 6A , Fsw = 91.6kHz Ch1 : Vds, Ch2 : VFB, Ch3 : Vrsense ( Rsense = 0R15) Ch4 (5Amp/V) : Output rectifier current @90Vac input ,Iout = 3A , Fsw = 88.5kHz Ch1 : Vds, Ch2 : VFB, Ch3 : Vrsense ( Rsense = 0R15) Ch4 (5Amp/V) : Output rectifier current @265Vac input ,Iout = 3A , Fsw ~ 145kHz Ch1 : Vds, Ch2 : VFB, Ch3 : Vrsense ( Rsense = 0R15) Ch4 (5Amp/V) : Output rectifier current www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 9 of 11 IRISMPS5 265Vac 90Wload OVP @265Vac input Iout = 0A , Fsw : 326kHz Ch1 :Vds, Ch2 : Vfb , Ch3 : Vrsense (Rsense : 0R15) @ 90Vac input , Ch2 ( Vout dynamic response ) Ch3 (5Amp/V) : Iout, Ch4 : Vout Dynamic loading 1Amp 5msec- 6Amp 5msec @ 90Vac input , Iout = 0A , Fsw : 306kHz Ch1 :Vds, Ch2 : Vfb , Ch3 : Vrsense (Rsense : 0R15) 265Vac Output Short ckt. @265Vac input , Ch2 ( Vout dynamic response ) Ch3 (5Amp/V) : Iout), Ch4 : Vout Dynamic loading 1Amp 5msec - 6Amp 5msec www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 10 of 11 IRISMPS5 Efficiency Graph I R I SM P S5 9 0 W Ful l oa d E f f i c i e nc y gr a ph 87. 00 86. 00 85. 00 84. 00 83. 00 82. 00 81. 00 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 A C i nput V ol t age Efficiency vs Output Power 90 85 Efficiency (%) 80 90Vac 75 115Vac 230Vac 70 265Vac 65 60 55 15W 30W 45W 60W 75W 90W Output Power (W) www.irf.com REFERENCE DEMO BOARD DOCUMENT Name : IRISMPS5_USERGUIDE_Rev2 DATE : 5/28/2004 MODEL : IRISMPS5 PN:1950-1001_Rev.2 Page 11 of 11