Design Example Report Title 22 W (48.6 W peak) 3 Output Power Supply Using TOP258MN 85 VAC – 265 VAC Input; 12 V, 40 - 800 mA (3 A peak, 50 ms); 8 V, 25 Specification 75 mA; 40 V, 30 - 300 mA Outputs 0 to +65°C Application Fresh Air Filter Author Applications Engineering Department Document Number DER-217 Date February 11, 2010 Revision 1.0 Summary and Features 48.6 W peak power from a DIP package with no heatsink Highly energy efficient Full load efficiency >80% Peak load efficiency >83% Low cost, low component count and small PCB footprint solution Performance met without TOPSwitch®-HX heatsink 132 kHz operation optimized core size and efficiency performance Integrated Protection and Reliability Features Line under-voltage lock out (UVLO) Auto recovery output over current (OCP) Accurate thermal shutdown with large hysteresis PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) 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 grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 Table of Contents 1 2 3 4 Introduction.................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic...................................................................................................................5 Circuit Description ......................................................................................................6 4.1 Input Stage and EMI Filtering ..............................................................................6 4.2 TOPSwitch-HX Primary .......................................................................................6 4.3 Output Rectification .............................................................................................7 4.4 Output Feedback.................................................................................................7 5 PCB Layout ................................................................................................................8 6 Bill of Materials ...........................................................................................................9 7 Transformer Specification.........................................................................................11 7.1 Electrical Diagram .............................................................................................11 7.2 Electrical Specification ......................................................................................11 7.3 Materials............................................................................................................11 7.4 Transformer Build Diagram ...............................................................................12 7.5 Transformer Construction..................................................................................12 8 Transformer Design Spreadsheet.............................................................................13 9 Performance Data ....................................................................................................17 9.1 Efficiency ...........................................................................................................17 9.2 Cross Regulation...............................................................................................19 9.2.1 Cross Regulation at 85 VAC ......................................................................19 9.2.2 Cross Regulation at 265 VAC ....................................................................19 10 Thermal Performance ...........................................................................................20 11 Waveforms............................................................................................................21 11.1 Drain Voltage at 265 VAC (Peak Load) .............................................................21 11.2 Start-up Voltage Profile .....................................................................................21 11.3 Diode Peak Inverse Voltage ..............................................................................23 11.4 Output Ripple Measurements............................................................................25 11.4.1 Ripple Measurement Technique ................................................................25 11.4.1 Measurement Results ................................................................................26 12 Conducted EMI .....................................................................................................28 13 Revision History ....................................................................................................29 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. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 1 Introduction This document is an engineering report describing a power supply for a fresh-air filter application utilizing TOP258MN (TOPSwitch®-HX family). The power supply has three outputs as follows: 40 V, 0.3 A, 12 V, 0.8 A (3 A peak) and 8 V, 75 mA. This document contains the power supply specification, schematic, bill of materials, transformer documentation and performance data. Figure 1 – Populated Circuit Board Photograph. Page 3 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 2 Power Supply Specification The table below represents the minimum acceptable performance of the design. Actual performance is listed in the results section. Description Input Voltage Frequency No-load Input Power (265 VAC) 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 Full Load Symbol Min VIN fLINE 85 47 Typ Max Units Comment VAC Hz mW 2 wire 50/60 265 64 300 8 VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 25 IOUT2 0.04 75 12 500 75 500 3 A 0.3 500 0.3 V mV A POUT 22 48.6 W 84 VOUT3 VRIPPLE3 IOUT3 0.8 V mV mA V mV 40 0.03 % 15% 20 MHz bandwidth 5% 20 MHz bandwidth 0.8 A in steady state, 3 A peak for 50 ms 10% 20 MHz bandwidth o Measured at 25 C Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Ambient Temperature TAMB 0 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 65 o C Free convection, sea level Page 4 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 3 Schematic Figure 2 – Schematic. Page 5 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 4 Circuit Description This circuit is an isolated flyback converter for a fresh air filter using TOP258MN. It is designed to operate from 85 VAC to 265 VAC. The power supply has three outputs, 40 V, 0.3 A, 12 V, 0.8 A (3 A peak), and 8 V, 75 mA. It delivers a steady state power of 22 W and a peak power of 48.6 W for 50 msec. Figure 2 shows the schematic. 4.1 Input Stage and EMI Filtering Fuse F1 protects the power supply against circuit faults such as short circuits (e.g. failure of the bridge rectifier). The bridge rectifier D2 is a full bridge rectifier circuit that rectifies the AC voltage into DC voltage. Capacitor C9 acts as filtering capacitor of the AC rectified waveform and also as the energy storage element of the power supply to provide a constant DC voltage. The common-mode choke L1, X capacitor C12, and Y capacitor C2 are used for EMI filtering. Resistor R8 aids in discharging the X capacitor within one second after input AC is turned off to prevent shock hazard but is not required to meet safety as C12 is only 100 nF. Capacitor C10 reduces the PCB layout primary switching current loop size, reducing EMI. The frequency jitter function of the TOPSwitch-HX family greatly reduces the size and complexity of the EMI filter components 4.2 TOPSwitch-HX Primary This design uses two clamp networks, one to limit maximum drain voltage across the primary winding and a snubber to limit rate-of-rise of the drain voltage connected across DRAIN and SOURCE of U1. The clamp circuit consists of D4, R3, VR1, and C5. During turn-off of the primary switching MOSFET, the energy stored in the leakage inductance of the primary winding of the transformer creates a voltage spike whose voltage level could exceed breakdown voltage (BVDSS) of the MOSFET. During turn-off, when the drain voltage rises to a voltage above the DC bus plus the voltage across C5, D4 conducts and C5 is charged. The voltage across C5 is maintained to between 1.5 and 2 times the reflected output voltage (VOR), determined by the value or R3. During a transient condition such as startup or a step change in load, the TVS (Transient Voltage Suppressor) VR1 prevents the voltage across the primary winding from rising above its rated value (200 V in this case). This allows the values of C5 and R3 to be optimized for normal operation, maximizing efficiency and reducing EMI while VR1 guarantees sufficient margin to BVDSS during peak and over-load conditions. The rate-of-rise snubber consists of D7, R10, and C14. During turn-off of the MOSFET, the leakage energy is dumped into the capacitor C13 through D6 and prevents the high drain dv/dt. The capacitor discharges through R10 at turn on. This snubber helps in Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN improving high frequency (radiated) EMI by decreasing the slope of the rising voltage on the drain of the MOSFET. 4.3 Output Rectification The output uses a combination of Schottky and ultrafast diodes. Schottky barrier type are used on the lower voltage outputs (where the diode reverse voltage stress allows their use) to improve efficiency due to their lower forward voltage (VF). RC snubbers (R1-C1, R9-C11, and R2-C4 on D1, D6, and D3 respectively) provide filtering of the voltage spike during turn-off of the diodes due to the reverse recovery characteristics and output leakage inductance which can cause significant EMI. 4.4 Output Feedback The output is regulated using a TL431 circuit to maintain 5% regulation. The TL431 pulls current through the photodiode of U2 when the voltage on the reference pin set by the voltage divider (R6, R7 and R17) goes higher than 2.5 V. As the current through the optocoupler increases current into the CONTROL pin of U1 also increases, reducing the duty cycle of the internal MOSFET and therefore maintaining output regulation. An additional soft-start circuit has also been implemented using C18, D8, and R11. Once the output voltage exceeds approximately 1.8 V (VF of the LED within U2 + VF of D8) C18 will begin to charge. As this charging current flows through U2 current will be also fed into the CONTROL pin of U1 (once the bias winding voltage is high enough to bias the optocoupler transistor). This effectively closes the control loop prior to the output reaching regulation and allows the output voltage rise time to be controlled during startup to prevent output overshoot. Resistor R11 discharges the soft-start capacitor during power supply shut down. Capacitor C13 and Resistor R14 are responsible for providing loop compensation. Page 7 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 5 PCB Layout The transformer secondary ground pin (pin 9) was selected to be in the center of the bobbin to reduce the loop areas of the individual outputs to reduce leakage inductance, improving cross regulation and EMI generation. As the SOURCE pins of U1 were connected to the large area of copper on the PCB as these pins provide heatsinking of the device. Figure 3 – PCB Layout. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 6 Bill of Materials Item Qty Ref Des Description 1 1 C1 Capacitor, 470 pF, 1 kV, Disc Ceramic 2 1 C2 Capacitor, 2.2 nF, Ceramic, Y1, 250VAC 3 1 C3 Capacitor, 220 F, 63 V, Electrolytic, Low ESR 4 2 C4 C11 Capacitor, 470 pF, 100 V, Ceramic, X7R, 1206 5 2 C5 C10 Capacitor, 2.2 nF, 1 kV, Disc Ceramic 6 2 C6 C7 7 1 8 1 9 Mfg Part Number Manufacturer 562R10TST47 Vishay 440LD22-R Vishay ELXZ630ELL221MJ25S Nippon Chemi-Con NCD222K1KVY5FF NIC Components Capacitor, 680 F, 25 V, Electrolytic, Very Low ESR EKZE250ELL681MJ20S Nippon Chemi-Con C8 Capacitor, 220 F, 16 V, Electrolytic KME16VB221M8X11LL Nippon Chemi-Con C9 Capacitor, 100 F, 400 V, Electrolytic ECO-S2GP101CA Panasonic 1 C12 Capacitor, 100 nF, 275VAC, Film, X2 F1772-410-2000 Vishay/Roederstein 10 2 C13 C15 Capacitor, 100 nF, 50 V, Ceramic, X7R, 0805 ECJ-2YB1H104K Panasonic 11 1 C14 Capacitor, 100 pF, 1 kV, Disc Ceramic ECC-D3A101JGE Panasonic - ECG 12 1 C16 C18 Capacitor, 10 F, 50 V, Electrolytic, Gen. Purpose EKMG500ELL100ME11D Nippon Chemi-Con 13 1 C17 Capacitor, 47 F, 10 V, Electrolytic, Gen. Purpose KME10VB22RM5X11LL Nippon Chemi-Con 14 1 D1 Diode, 400 V, 1 A, Ultrafast Recovery, 35 ns, SMB MURS140T3 On Semi 15 1 D2 Diode, 1000 V, 4 A, Bridge Rectifier KBL10-E4/51 Vishay Diode, 100 V, 3 A, Schottky, SMC 30BQ100 International Rectifier Diode, Ultra Fast, 800V, 1 A, SMA US1K-13-F Diodes, Inc D3 Epcos 16 1 17 4 18 1 D4 D5 D7 D8 D6 SGL41-60/96 Vishay 19 1 F1 Fuse, 3.5 A, 250 V, Slow, 5 mm x 20 mm, Axial 23003.5 Littelfuse 20 1 L1 Inductor, 15 mH, 1.0 A, Common Mode Choke ELF-18D431F Panasonic 21 3 R1 R2 R9 Resistor, 47 , 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ470V Panasonic 22 1 R3 Resistor, 100 k, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ104V Panasonic 23 1 R4 Resistor, 3.9 M, 5%, 1/2 W, Carbon Film 24 1 R5 Resistor, 2.2 , 5%, 1/8 W, Metal Film, 0805 25 1 R6 Resistor, 150 k, 1%, 1/8 W, Metal Film, 0805 ERJ-6ENF1503V Panasonic 26 27 28 1 1 1 R7 R8 R10 Resistor, 38.3 k, 1%, 1/8 W, Metal Film, 0805 Resistor, 2 M, 5%, 1/2 W, Carbon Film Resistor, 22 k, 5%, 1/4 W, Metal Film, 1206 ERJ-6ENF3832V CFR-50JB-2M0 ERJ-8GEYJ223V Panasonic Yageo Panasonic 29 1 R11 Resistor, 10 k, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ103V Panasonic 30 1 R12 Resistor, 5.1 k, 5%, 1/8 W, Metal Film, 0805 ERF-6ENF1503V Panasonic 31 1 R13 Resistor, 2 k, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ202V Panasonic 32 1 R14 Resistor, 3.3 k, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ332V Panasonic 33 1 R15 Resistor, 6.8 , 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ6R8V Panasonic 34 1 R16 Resistor, 10.5 k, 1%, 1/8 W, Metal Film, 0805 ERJ-6ENF1052V Panasonic 35 1 R17 Resistor, 4.87 k, 1%, 1/4 W, Metal Film, 1206 ERJ-8ENF4871V Panasonic 36 1 RV1 MOV, 275 V, 75 J, 14 mm, RADIAL V275LA20A Littlefuse 37 1 T1 Bobbin, EER28L, Horizontal, 12 pins YC2806 Ying Chin TOP258MN Power Integrations PC817X4 Sharp Diode, 60 V, 1 A, Schottky, SMD, DO-213AB 38 1 U1 IC, TOPSwitch-HX, TOP258MN, SDIP-10 39 1 U2 IC, Optocoupler, 35 V, CTR 300-600%, 4-DIP Page 9 of 30 CFR-50JB-3M9 Yageo ERJ-6GEYJ2R2V Panasonic Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 40 1 U3 41 1 VR2 IC, 2.495 V Shunt Regulator IC, 2%, 0 to 70C Diode, Zener, 18W, 500mW 42 1 VR1 Diode, TVS, 200 V, 1500 W, SMC Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com TL431CLPG 11-Feb-10 On Semiconductor 1N5248B Diodes, Inc SMCJ200A-13-F Diodes, Inc Page 10 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 7 Transformer Specification 7.1 Electrical Diagram Figure 4 – Transformer Electrical Diagram. 7.2 Electrical Specification Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 60 Hz 1 second, from pins 1-6 to pins 7-12. Pin 1 to pin 3, all other windings open, measured at 100 kHz, 1 VRMS. All windings open. 3000 VAC 590 H, 10% 850 kHz (Min.) 7 H (Max.) Pins 1-3, all other pins shorted. Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description 3 mm margin tape 3M barrier tape: polyester film Core: 1 pair EER28L TDK PC44 or equivalent Bobbin: 12 pin EER28L, horizontal, Ying Chin, YC2806 Magnet wire: #24 AWG double coated Magnet wire: #26 AWG double coated Magnet wire: #28 AWG double coated Copper foil Varnish Page 11 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 7.4 11-Feb-10 Transformer Build Diagram 1 1 2 6 5 11 12 9 7,8 7,8 11 1 2 3 Figure 5 – Transformer Build Diagram. 7.5 Transformer Construction All windings are wound in the same direction. Margin tape Primary Winding Insulation Shield Insulation Secondary Winding Insulation Secondary Winding Insulation Bias Winding Insulation Primary Winding Insulation Assembly Flux band Insulation Final Assembly Wind 3mm margin tape on both sides of the bobbin to match the height of the first half of the primary winding. Repeat for each subsequent layer. Start from left to right from pin 3. Wind 31 turns of #26 AWG wire on one layer. Return end back to start side and terminate on pin 2. Use one layer of tape. Place one layer of copper foil for shield and terminate at pin 1. Place two layers of tape. Start from left to right start 3 turns of 3x #24 AWG wire from pin 11 and started 5 turns of 3x #24 AWG wire from pin 7 and 8 in bifilar fashion. Terminate the first winding at pin 7 and 8 and the second winding at pin 9. Place one layer of tape. Start from left to right from pin 12. Wind 17 turns of 3x #28 AWG magnet wire on one layer. Terminate at pin 11. Place two layers of tape. Start from left to right from pin 5. Wind 10 turns of 2x #28 AWG wire on one layer. Terminate on pin 6. Spread winding evenly in the bobbin. Use one layer of tape. Start from left to right from pin 2. Wind 32 turns of #26 AWG wire on one layer. Terminate at pin 1. Place two layers of tape. Assembly and secure core halves. Place one turn of shorted copper foil touching the core and terminate to pin 1. Place two layers of tape. Dip varnish – DO NOT VACUUM IMPREGNATE. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 8 Transformer Design Spreadsheet ACDC_TOPSwitchHX_0 21308; Rev.1.8; Copyright Power Integrations 2008 INPUT ENTER APPLICATION VARIABLES VACMIN 85 VACMAX 265 fL 50 VO 12.00 PO_AVG 22.00 PO_PEAK 48.64 n 0.80 Z 0.50 VB 15 tC 3.00 INFO OUTPUT 48.64 UNIT Volts Volts Hertz Volts Watts Watts %/100 Volts mSeconds CIN 100.0 ENTER TOPSWITCH-HX VARIABLES TOPSwitch-HX TOP258MN 100 uFarads Power Out Universal / Peak 35 W / 92 W ILIMITMIN_EXT 2.009 Amps ILIMITMAX_EXT 2.311 Amps Chosen Device KI Frequency (F)=132kHz, (H)=66kHz TOP258MN 0.72 H H fS 66000 Hertz fSmin 59400 Hertz fSmax 72600 Hertz High Line Operating Mode VOR VDS FF 100.00 10 Volts Volts VD 0.60 Volts VDB 0.70 Volts KP 0.60 PROTECTION FEATURES LINE SENSING VUV_STARTUP 95 Volts VOV_SHUTDOWN 445 Volts RLS 4.0 M-ohms OUTPUT OVERVOLTAGE VZ 27 Volts RZ 5.1 k-ohms Page 13 of 30 TOP_HX_021308: TOPSwitch-HX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage (main) Average Output Power Peak Output Power Efficiency Estimate Loss Allocation Factor Bias Voltage Bridge Rectifier Conduction Time Estimate Input Filter Capacitor 115 Doubled/230V 48W External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Half frequency option is only available for P, G and M packages in addition to TOP259-TOP261YN devices. For full frequency operation choose E package or TOP254-TOP258YN devices. TOPSwitch-HX Switching Frequency: Choose between 132 kHz and 66 kHz TOPSwitch-HX Minimum Switching Frequency TOPSwitch-HX Maximum Switching Frequency Full Frequency, Jitter enabled Reflected Output Voltage TOPSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.3 < KRP < 1.0 : 1.0< KDP<6.0) Minimum DC Bus Voltage at which the power supply will start-up Typical DC Bus Voltage at which power supply will shut-down (Max) Use two standard, 2 M-Ohm, 5% resistors in series for line sense functionality. Zener Diode rated voltage for Output Overvoltage shutdown protection Output OVP resistor. For latching Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 shutdown use 20 ohm resistor instead OVERLOAD POWER LIMITING Overload Current Ratio at VMAX 1.2 Overload Current Ratio at VMIN ILIMIT_EXT_VMIN ILIMIT_EXT_VMAX RIL RPL Info 5.08 1.88 1.92 8.78 N/A ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EER28L EER28L Core EER28L Bobbin EER28L_ BOBBIN AE 0.814 LE 7.55 AL 2520 BW 21.8 M 3.00 L NS 2.00 8 A A k-ohms M-ohms P/N: P/N: cm^2 cm nH/T^2 mm mm 8 DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.60 IAVG 0.36 Amps IP 1.88 Amps IR 0.51 Amps IRMS 0.48 Amps TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP Tolerance NP NB ALG BM 589 10 63 10 146 2144 uHenries BP 2895 Gauss BAC 643 Gauss ur 1860 LG BWE OD 0.66 31.6 0.50 mm mm mm INS 0.07 mm DIA 0.43 mm Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 77 373 Volts Volts nH/T^2 Gauss Enter the desired margin to current limit at VMAX. A value of 1.2 indicates that the current limit should be 20% higher than peak primary current at VMAX Your margin to current limit at low line is high. Reduce KI to 0.24 (if possible). Peak primary Current at VMIN Peak Primary Current at VMAX Current limit/Power Limiting resistor. Resistor not required. Use RIL resistor only Core Type PC40EER28L-Z BEER-28L-1112CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Minimum DC Input Voltage Maximum DC Input Voltage Maximum Duty Cycle (calculated at PO_PEAK) Average Primary Current (calculated at average output power) Peak Primary Current (calculated at Peak output power) Primary Ripple Current (calculated at average output power) Primary RMS Current (calculated at average output power) Primary Inductance Tolerance of Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns Gapped Core Effective Inductance Maximum Flux Density at PO, VMIN (BM<3000) Peak Flux Density (BP<4200) at ILIMITMAX and LP_MAX. Note: Recommended values for adapters and external power supplies <=3600 Gauss AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Page 14 of 30 11-Feb-10 AWG DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN Primary Wire Gauge (Rounded to next smaller standard AWG value) CM 256 Cmils Bare conductor effective area in circular mils CMA 539 Cmils/Amp !!! DECREASE CMA> (decrease Warning L(primary layers),increase NS,smaller Core) Primary Current Density 3.71 Amps/mm^2 !!! Info. Primary current density is low. (J) Can increase Primary current density. Reduce primary layers, or use smaller core TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 14.94 Amps Peak Secondary Current ISRMS 3.09 Amps Secondary RMS Current IO_PEAK 4.05 Amps Secondary Peak Output Current IO 1.83 Amps Average Power Supply Output Current IRIPPLE 2.49 Amps Output Capacitor RMS Ripple Current CMS 618 Cmils Secondary Bare Conductor minimum circular mils AWGS 22 AWG Secondary Wire Gauge (Rounded up to next larger standard AWG value) DIAS 0.65 mm Secondary Minimum Bare Conductor Diameter ODS 1.98 mm Secondary Maximum Outside Diameter for Triple Insulated Wire INSS 0.66 mm Maximum Secondary Insulation Wall Thickness VOLTAGE STRESS PARAMETERS VDRAIN 573 Volts Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) PIVS 59 Volts Output Rectifier Maximum Peak Inverse Voltage PIVB 74 Volts Bias Rectifier Maximum Peak Inverse Voltage TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 12.00 12 Volts Output Voltage IO1_AVG 3.00 3.00 Amps Average DC Output Current PO1_AVG 36.00 Watts Average Output Power VD1 0.70 0.7 Volts Output Diode Forward Voltage Drop NS1 8.06 Output Winding Number of Turns ISRMS1 5.053 Amps Output Winding RMS Current IRIPPLE1 4.07 Amps Output Capacitor RMS Ripple Current PIVS1 59 Volts Output Rectifier Maximum Peak Inverse Voltage CMS1 1011 Cmils Output Winding Bare Conductor minimum circular mils AWGS1 20 AWG Wire Gauge (Rounded up to next larger standard AWG value) DIAS1 0.81 mm Minimum Bare Conductor Diameter ODS1 1.96 mm Maximum Outside Diameter for Triple Insulated Wire 2nd output VO2 40.00 Volts Output Voltage IO2_AVG 0.30 Amps Average DC Output Current PO2_AVG 12.00 Watts Average Output Power VD2 0.60 0.6 Volts Output Diode Forward Voltage Drop NS2 25.78 Output Winding Number of Turns ISRMS2 0.505 Amps Output Winding RMS Current IRIPPLE2 0.41 Amps Output Capacitor RMS Ripple Current PIVS2 192 Volts Output Rectifier Maximum Peak Inverse Voltage CMS2 101 Cmils Output Winding Bare Conductor minimum circular mils Page 15 of 30 26 AWG Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN AWGS2 DIAS2 ODS2 3rd output VO3 IO3_AVG PO3_AVG VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 30 AWG 0.26 0.61 mm mm 7.50 0.08 0.60 0.6 5.14 0.135 0.11 38 0.60 Volts Amps Watts Volts Amps Amps Volts CMS3 27 Cmils AWGS3 35 AWG 0.14 3.07 mm mm 48.6 Watts DIAS3 ODS3 Total Continuous Output Power Warning Negative Output N/A 11-Feb-10 Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Output Voltage Average DC Output Current Average Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire !!! Warning. Total Continuous Output power does not match with the power entered under 'Applications Variables' section If negative output exists enter Output number; eg: If VO2 is negative output, enter 2 Note: The CMA warning can be ignored as this indicates more copper area is available than needed for the secondary winding. High CMA (low current density) in a winding does not create a design problem. The continuous power warning at the end of the design spreadsheet is the result of a rounding error 48.6 W vs. 48.64 W entered at top of spreadsheet Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency Figure 6 – Efficiency at Steady State Load 22.2 W vs. Input Voltage. Page 17 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 85.4 85.2 Efficiency (%) 85 84.8 84.6 84.4 84.2 84 83.8 83.6 80 105 130 155 180 205 230 255 Input Voltage (VAC) Figure 7 – Efficiency at Peak Load vs. Input Voltage. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 30 11-Feb-10 9.2 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN Cross Regulation 9.2.1 Cross Regulation at 85 VAC Minimum load: 8 V at 25 mA, 12 V at 40 mA, 40 V at 30 mA Full load: 8 V at 75 mA, 12 V at 800 mA, 40 V at 300 mA 8V Min. load Min. load Min. load Min. load Full load Full load Full load Full load Output Load 12 V Min. load Min. load Full load Full load Min. load Min. load Full load Full load 40 V Min. load Full load Min. load Full load Min. load Full load Min. load Full load Measured Output Voltage 8V 12 V 40 V 7.5 12.41 39.5 7.63 12.5 39.2 7.55 12.01 41 7.73 12.32 39.9 7.28 12.41 39.5 7.48 12.52 39.1 7.41 12.02 40.9 7.63 12.31 39.7 9.2.2 Cross Regulation at 265 VAC Minimum load: 8 V at 25 mA, 12 V at 40 mA, 40 V at 30 mA Full load: 8 V at 75 mA, 12 V at 800 mA, 40 V at 300 mA 8V Min. load Min. load Min. load Min. load Full load Full load Full load Full load Page 19 of 30 Output Load 12 V Min. load Min. load Full load Full load Min. load Min. load Full load Full load 40 V Min. load Full load Min. load Full load Min. load Full load Min. load Full load Measured Output Voltage 8V 12 V 40 V 7.47 12.4 39.6 7.62 12.51 39.1 7.56 12.04 40.8 7.22 12.32 39.9 7.22 12.4 39.6 7.49 12.5 39.1 7.43 12.04 40.9 7.63 12.31 39.9 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 10 Thermal Performance Thermal tests were conducted at worst case condition of 85 VAC with 22 W Load. Component Bulk capacitor Drain snubber diode Output diode (8 V) Output diode (12 V) Output diode (40 V) Output capacitor (8 V) Output capacitor (12 V) Output capacitor (40 V) Transformer TOP258MN Bridge rectifier TVS dv/dt snubber diode Measured at 25 ºC 35 45 42.1 68 64.5 37.9 42.4 38.7 53.9 51.3 40.6 47.8 45.2 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Calculated for 65 ºC 75 85 82.1 108 104.5 77.9 82.4 78.7 93.9 91.3 80.6 87.8 85.2 Page 20 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11 Waveforms 11.1 Drain Voltage at 265 VAC (Peak Load) Figure 8 – 265 VAC. VDRAIN, 100 V / div., 2.5 μs / div. 11.2 Start-up Voltage Profile Figure 9 – Output Voltage at 85 VAC, 8 V at 25 mA, 12 V at 40 mA, 40 V at 30 mA. Upper Trace: 40 V, 10 V / div., 250 ms / div. Middle Trace: 12 V, 5 V / div., 250 ms / div. Bottom Trace: 8 V, 5 V / div., 250 ms / div. Page 21 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 Figure 10 – Output Voltage at 265 VAC, 8 V at 25 mA, 12 V at 40 mA, 40 V at 30 mA. Upper Trace: 40 V, 10 V / div., 250 ms / div. Middle Trace: 12 V, 5 V / div., 250 ms / div. Bottom Trace: 8 V, 5 V / div., 250 ms / div. Figure 11 – Output Voltage at 85 VAC, Peak Load. Upper Trace: 40 V, 10 V / div., 250 ms / div. Middle Trace: 12 V, 5 V / div., 250 ms / div. Bottom Trace: 8 V, 5 V / div., 250 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN Figure 12 – Output Voltage at 265 VAC, Peak Load. Upper Trace: 40 V, 10 V / div., 250 ms / div. Middle Trace: 12 V, 5 V / div., 250 ms / div. Bottom Trace: 8 V, 5 V / div., 250 ms / div. 11.3 Diode Peak Inverse Voltage Figure 13 – Output Diode PIV, 8 V Diode, 265 VAC, Peak Load 10 V / div., 1 μs / div. Page 23 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 Figure 14 – Output Diode PIV, 12 V Diode, 265 VAC, Peak Load 20 V / div., 1 μs / div. Figure 15 – Output Diode PIV, 40 V Diode, 265 VAC, Peak Load 50 V / div., 1 μs / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11.4 Output Ripple Measurements 11.4.1 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 the figures below. The 4987BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/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 16 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 17 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter. (Modified with wires for ripple measurement, and two parallel decoupling capacitors added) Page 25 of 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 11.4.1 Measurement Results Figure 18 – Output Voltage Ripple 8 V, 85 VAC at Peak Load. 100 mV / div., 5 μs / div. Figure 19 – Output Voltage Ripple 8 V, 265 VAC at Peak Load. 100 mV / div., 10 μs / div. Figure 20 – Output Voltage Ripple 12 V, 85 VAC at Peak Load. 100 mV /div., 5 μs / div. Figure 21 – Output Voltage Ripple 12 V, 265 VAC at Peak Load. 100 mV / div., 5 μs / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN Figure 22 – Output Voltage Ripple 40 V, 85 VAC at Peak Load.500 mV / div., 5 μs / div. Page 27 of 30 Figure 23 – Output Voltage Ripple 40 V, 265 VAC at Peak Load. 200 mV / div., 10 μs / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 12 Conducted EMI The upper and lower limits shown are quasi peak and the average limits as per EN55022 Class B. A resistive load was connected to DC output terminals. Measurements shown are peak measurements vs. QP and AVG limits. RBW MT 19.Aug 08 11:45 9 kHz 1 s Att 10 dB AUTO dBµV 1 MHz 100 10 MHz 90 1 PK CLRWR SGL 80 2 AV CLRWR TDF 70 EN55022Q 60 EN55022A 50 6DB 40 30 20 10 0 150 kHz 30 MHz Figure 24 – Conducted EMI, 115 VAC, Neutral. RBW MT 19.Aug 08 11:46 9 kHz 1 s Att 10 dB AUTO dBµV 1 MHz 100 10 MHz 90 1 PK CLRWR 2 AV CLRWR SGL 80 TDF 70 EN55022Q 60 EN55022A 50 6DB 40 30 20 10 0 150 kHz 30 MHz Figure 25 – Conducted EMI, 265 VAC, Neutral. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 30 11-Feb-10 DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 13 Revision History Date 11-Feb-10 Page 29 of 30 Author EC, SPM Revision 1.0 Description & changes Initial release Reviewed Apps & Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-217 22 W (48.6 W peak) Power Supply Using TOP258MN 11-Feb-10 For the latest updates, visit our website: 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. POWER INTEGRATIONS MAKES NO WARRANTY 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 transformer construction and circuits external to the products) 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 grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2010 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. 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