Title Reference Design Report for 14.5 W Standby and 300 W Main Power Supply Using HiperTFS™ TFS762HG Specification 300 VDC – 385 VDC Input; 5 V, 2.9 A (Standby) and 12 V, 25 A (Main) Outputs Application PC Power Supply Author Applications Engineering Department Document Number RDR-249 Date November 16, 2011 Revision 1.1 Summary and Features High efficiency Main and Standby converters Remote on/off Built-in main and standby undervoltage thresholds protection ensures graceful power supply start-up and shutdown Latching output overvoltage protection Integrated high-side driver Output short-circuit and open loop protection Main transformer reset protection Flat standby overload versus input voltage 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 RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 Table of Contents 1 2 3 4 Introduction ................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic ................................................................................................................... 6 Circuit Description ...................................................................................................... 7 4.1 Power Input and Filter ......................................................................................... 7 4.2 Primary Side ........................................................................................................ 7 4.3 Output Rectification ............................................................................................. 8 4.4 Output Feedback ................................................................................................. 9 4.5 Output Overvoltage Protection ............................................................................ 9 5 PCB Layout .............................................................................................................. 10 6 Bill of Materials ......................................................................................................... 12 7 Standby Transformer Specification........................................................................... 15 7.1 Electrical Diagram ............................................................................................. 15 7.2 Electrical Specifications ..................................................................................... 15 7.3 Materials ............................................................................................................ 15 7.4 Transformer Build Diagram ............................................................................... 16 7.5 Transformer Construction .................................................................................. 16 8 Main Transformer Specification ................................................................................ 17 8.1 Electrical Diagram ............................................................................................. 17 8.2 Electrical Specifications ..................................................................................... 17 8.3 Materials ............................................................................................................ 17 8.4 Transformer Build Diagram ............................................................................... 18 8.5 Transformer Construction .................................................................................. 19 9 Main Output Inductor Specification ........................................................................... 20 9.1 Electrical Diagram ............................................................................................. 20 9.2 Electrical Specifications ..................................................................................... 20 9.3 Materials ............................................................................................................ 20 9.4 Winding Instructions .......................................................................................... 20 9.5 Inductor Illustrations .......................................................................................... 20 10 Transformer Design Spreadsheet ......................................................................... 21 11 Performance Data ................................................................................................. 27 11.1 Main and Standby Efficiency ............................................................................. 27 11.2 Full Power Standby Efficiency vs. Equivalent AC Input Voltage ........................ 28 11.3 Standby Efficiency vs. Output Power ................................................................ 29 11.4 Standby Only No-Load Input Power .................................................................. 30 11.5 Main and Standby Voltage Regulation .............................................................. 31 11.5.1 Main Load Regulation ................................................................................ 31 11.5.2 Standby Load Regulation at Equivalent AC Input Voltages........................ 32 11.5.3 Standby Line Regulation at Full Power ...................................................... 33 12 Thermal Performance ........................................................................................... 34 13 Waveforms ............................................................................................................ 35 13.1 Main Drain Voltage and Current, Normal Operation, Full Power ....................... 35 13.2 Standby Drain Voltage and Current, Normal Operation, Full Power .................. 36 13.3 Standby Drain Current and Output Voltage Start-Up Profile.............................. 37 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 13.4 Main Drain Current, and Main and Standby Output Voltage Start-Up Profile ....38 13.5 Main Output Voltage Remote-ON Start-Up Profile.............................................38 13.6 Main or Standby OV Shutdown .........................................................................39 13.7 Full Power Hold-Up Time ...................................................................................40 13.8 Standby Auto-Restart ........................................................................................40 13.9 Main and Standby Full Power Output Short-Circuit ...........................................41 13.10 Main Remote-ON/OFF ...................................................................................42 13.11 Output Ripple Measurements ........................................................................43 13.11.1 Ripple Measurement Technique .............................................................43 13.11.2 Measurement Results .............................................................................44 13.12 Main and Standby Load Transient Response ................................................45 14 Design Notes: ........................................................................................................46 15 Revision History ....................................................................................................47 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 AC isolation transformer to the DC power supply or power factor stage used to provide the input voltage. Page 3 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 1 Introduction This document is an engineering report describing a 5 V, 2.9 A Standby and a 12 V, 25 A Main power supply utilizing the TFS762HG device from the HiperTFS family. This example power supply uses a fixed DC input voltage, but in a typical application, it would be connected to a PFC boost input stage, delivering approximately 385 VDC to implement a 300 W power supply with various output voltages. A lab bench DC power supply capable of 400 VDC at 3 A or an AC input rectifier stage is required supply to the input for evaluation. It is also possible to use the power factor circuit RDK-236 to provide the regulated 385 VDC needed to power RDK-249. Typically PC power supplies have a universal AC input power factor corrected (PFC) input stage but as the bias standby supply must operate before the PFC stage is active, the Standby output must operate with the DC equivalent of universal AC input voltages (85 VAC to 265 VAC and 100 VDC to 400 VDC). 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. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 2 Power Supply Specification The table below represents the minimum acceptable performance of the design. Actual performance is listed in the results section. Description Symbol Min Typ Max Units Comment VIN VIN PIN 100 300 420 420 0.3 VDC VDC W Equivalent to 85 VAC - 295 VAC 380 VOUT1 IOUT1 VRIPPLE1 4.75 0.04 5.25 5 50 V A mV 5%, 40 mA minimum load Output Voltage 2 (main 12 V) VOUT2 Output Current 2 (main 12 V) IOUT2 Output Ripple Voltage 2 (main 12 V) VRIPPLE2 11.4 0.1 12.00 12.6 25 28.33 120 V A mV 5%, 100mA minimum load 14.5 300 314.5 380 W W W W ms For Standby only For both Main and Standby % 100% Load % 100% Load Input Standby only Voltage Main and Standby Voltage No-load Input Power (324 VDC) Output Output Voltage 1 (standby) Output Current 1 (standby) Output Ripple Voltage 1 (standby) Total Output Power 1 Total Output Power 2 Total Output Power 3 Total Peak Output Power Holdup Time Efficiency Main and Standby Standby Only Ambient Temperature POUT1 POUT2 POUT3 PPEAK 5.00 2.9 THOLD_UP 20 ms 86.5 76 20 Equivalent to 230 VAC Standby only 10% 20MHz bandwidth 10% 20 MHz bandwidth For Main12 V only For both Main and Standby For POUT3 o Forced cooling, sea level 0 50 C TAMB Table 1 –Power Supply Specifications Using TFS762HG Note 1: All measurements performed with 380 VDC input unless otherwise specified Note 2: For output voltage tolerance and ripple see minimum/maximum allowed current Note 3: Total peak DC output power will not exceed 365 W at 50 oC with forced cooling Note 4: Peak Main power is 340 W (excluding Standby) Note 5: Absolute maximum Standby power is less than 25 W (excluding Main) Note 6: Full load operation at room temperature beyond 10 minutes requires a 30 CFM fan Page 5 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 3 Schematic Missing from this schematic are any mechanical/assembly part like mounting holes, screws, heat-sing brackets etc. Figure 2 – Schematic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 4 Circuit Description The HiperTFS TFS762HG cost effectively incorporates a low-side 725 V Main MOSFET, a high-side 530 V Main MOSFET and a 725 V Standby MOSFET, main and standby controllers, a high-side driver along with thermal shutdown and other fault protection and other control circuitry in a single package. The device is well suited for high power applications with both main and standby converter (such as PC power supplies). The standby operates over a wide input voltage range. The main converter is intended to accept boosted input voltage from a power-factor correction stage and normally operates over a range from 385 VDC to 300 VDC 4.1 Power Input and Filter This circuit is designed for PC power supplies with a Main output power up to 300 W. Diode D13 provides protection against catastrophic failure in case of reverse input voltage connection which would cause fuse F1 to open. Capacitor C1 is the bulk energy storage element providing energy for at least 20 ms at full load from 385 VDC initial input voltage. 4.2 Primary Side Components C2, R1, R6 and VR3 form a turn-off clamping circuit that limits the drain voltage of U6 for both the standby drain and the drain of the low-side Main Drain of the forward converter. Zener VR3 provides a defined clamp voltage and maintains a maximum voltage (150 V) on clamp capacitor C2. Most of the leakage and magnetizing energy is returned back to converter due to the slow recovery aspect of the general recovery diodes D3 and D4. Shared reset/leakage spike clamp between Main and Standby reduces component count. The Standby is connected via diode D3 and resistor R5 and the Main section is connected through D8 and D4 together with R7 and R8. During the reset time, the Main section is connected to a substantially higher reset voltage than VIN, hence the Main operating duty cycle of the Main converter can operate above 50% which lowers RMS switch currents without penalizing holdup time. The BYPASS (BP) pin along with C12 provides a decoupled operating voltage for the HiperTFS controller. At start-up the bypass capacitor is charged from an internal device current source. When the BP pin voltage reaches 5.8 V the standby converter will begin switching and both the +5 V standby output and primary-side bias voltage will begin to rise. The output of the bias/auxiliary supply winding is rectified by diode D12 and filtered by capacitor C20. Output of the bias winding is used to supply power via resistor R16 to the HiperTFS BP pin during standby only operation. Additional current is provided by Q1 and D10 by the primary bias supply when remote-on switch SW1 activates U3A and U3B and commands Q1 into an ON state. In a complete PC power supply application, this voltage is used to supply bias to the PFC controller through J4 connector. The value of R16 is selected to maintain the minimum 700 A required into BP pin to inhibit the internal HiperTFS high voltage current source and thus reduce no-load consumption. Capacitor C12 connected to the BP pin of U6 provides decoupling for the internally Page 7 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 regulated 5.85 V supply. Zener diode VR4 provides a voltage reference for Q1 to regulate the emitter voltage to 12.4 V for a stable 6 mA into BP pin. The ENABLE (EN) pin is the feedback pin for the Standby controller section. Prior to the start-up a resistor R27 connected from EN to BP can be detected to select on of several internal current limits for Standby section. FEEDBACK (FB) pin resistor R25 can also be used to select one of three Main current limits at start-up in the same manner as the EN pin. Four different resistor values can be used for R27 to select one of the four internal current limit configurations for the Standby section, and three different values for R25 to select one of the three current limit configurations for the Main section. The circuit presented here uses R27 (280 k) for a standby ILIM of 650 mA and R25 for a Main ILIM of 3.5 A. The FB pin provides feedback for the Main converter. An increase in current sink from FB pin to ground will lead to a reduction in the operating duty cycle. Diode D9 is used to provide the initial power for the bootstrap charging C3 and C6 during start-up. During this time the high-side MOSFET HS pin is briefly pulled to Source for 12 ms. Once the main converter begins switching after the initial 12 ms bootstrap delay, diode D5 is used to provide the internal nominal power for the high-side section from the Main transformer support winding, pins 1 and 2. The normal voltage on C6 during normal operation is shunt regulated to approximately 12 V. It is necessary to insure at all times a minimum of 13 V on C3. Resistors R18, R19, and R36 are used to translate the maximum available OFF time reset voltage into a current for the R pin and compare with the L pin current to compute the maximum allowable duty cycle to prevent saturation and also determines the maximum allowable duty factor as a function of peak on-time flux. The LINE-SENSE (L) pin provides an input bulk voltage line-sense function. This information is used by the under-voltage and over-voltage detection circuits for both the Main and standby sections. This pin can also be pulled down to SOURCE to implement a remote-ON/OFF of both the Standby and Main supplies simultaneously. Resistors R12, R13, and R35 are used to translate the input voltage into a current for L pin. 4.3 Output Rectification For the Standby section, output rectification is provided by diode D11. A low ESR capacitor, C17, provides filtering with low ripple. Inductor L2 and capacitor C15 form a post-filter to further reduce switching ripple and noise in the output. For the Main section diode D7 rectifies during Main on-time and diode D6 is the catch diode to provide a current discharge path for the output inductor, L1, during the Main offtime. Inductor L1 together with capacitors C10 and C11 form an output filter out switching output ripple and noise. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 4.4 Output Feedback For the Standby section, resistor R34 and R31 form a network divider. The output voltage of the power supply is divided and fed to the input terminal of error amplifier U7. The cathode terminal voltage of U2A is controlled by the amplifier inside U7 to maintain the divider voltage to 2.5 V +/-2%. Change in cathode terminal voltage results in a change of the current through optocoupler diode inside U2A, which in turn changes the current through the transistor inside U2B. Capacitor C19 provides strong noise rejection for the EN pin. When the current sinking from the EN pin exceeds the EN pin threshold current, the next switching cycle is inhibited, and when the output voltage falls below the feedback threshold, a conduction cycle is allowed to occur. By adjusting the number of enabled cycles, output regulation is maintained. As the load reduces, the number of enabled cycles decreases lowering the effective switching frequency and scales the switching losses with load. This provides almost constant efficiency down to very light loads, ideal for meeting energy efficiency requirements. For the Main section, resistors R9 and R24 are employed to provide the DC reference for the U5 error amplifier. In a similar manner, U5 controls the optocoupler U1 used to adjust the operating duty cycle trough the current sink from the FB pin with the main difference being the FB pin current controls the duty cycle of the main converter in a linear manner versus the whole cycle on/off control of the standby converter. 4.5 Output Overvoltage Protection The output OV protection for both Main and Standby is provided through optocoupler U4. If the feedback loop is broken or for any other internal or external reason, the output voltage increases over the maximum allowed limit, VR1 and/or VR2 are used to activate the protection circuit built around U4. When the output of U4B turns on, the current flow into the BP pin exceeds the latching shutdown threshold current of 15 mA. This will trigger the latching shutdown feature of HiperTFS and the device stops switching, protecting the output. The latching condition disables switching until the latch is reset with source current into the L pin below 10 A. Page 9 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 5 PCB Layout Figure 3 – Printed Circuit Layout, Bottom Side. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main Figure 4 – Printed Circuit Layout, Top Side. Page 11 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 6 Bill of Materials Item Qty Ref Des Description Mfg Part Number Mfg 1 1 C1 2 1 C2 270 F, 450 V, Electrolytic, (35 x 35) EET-ED2W271EA Panasonic 3.3 nF, 1 kV, Disc Ceramic NCD332M1KVZ5U NIC 3 4 C3 C4 C6 C8 4 1 C5 100 nF 25 V, Ceramic, X7R, 0603 ECJ-1VB1E104K Panasonic 47 nF 16 V, Ceramic, X7R, 0603 ECJ-1VB1C473K Panasonic 470 pF 50 V, Ceramic, X7R, 0603 5 1 C7 ECJ-1VC1H471J Panasonic 6 3 C9 C18 C19 1000 pF, 100 V, Ceramic, COG, 0603 C1608C0G2A102J TDK 7 2 C10 C11 3300 F, 16 V, Electrolytic, Very Low ESR, 15 m, (12.5 x 35) EKZE160ELL332MK35S Nippon Chemi-Con 8 1 C12 1 F, 16 V, Ceramic, X5R, 0603 GRM188R61C105KA93D Murata 9 1 C13 1 nF, 100 V, Ceramic, X7R, 0805 10 1 C14 470 nF, 50 V, Ceramic, Y5G, 0603 11 2 C15 C17 12 1 C16 330 nF, 16 V, Ceramic, Y5G, 0603 2200 F, 10 V, Electrolytic, Low ESR, (10 x 25) 13 1 C20 330 F, 35 V, Electrolytic, Low ESR, 68 m, (10 x 16) 14 1 C21 2.2 nF, Ceramic, Y1 ECJ-2VB2A102K Panasonic C1608Y5V1H474Z TDK 10MCZ1000M10X25 Rubycon ECJ-1VF1C334Z Panasonic ELXZ350ELL331MJ16S Nippon Chemi-Con 440LD22-R Vishay 15 1 D1 LED, Yellow, 5 mm, 585 nm, 30 mcd SSL-LX5093YD Lumex Opto 16 1 D2 LED, Green, 5 mm, 565 nm, 30 mcd SSL-LX5093GD Lumex Opto 17 2 D3 D4 1N4007-E3/54 Vishay 200 V, 200 mA, Fast Switching, 50 ns, DO-35 1000 V, 1 A, Rectifier, DO-41 BAV20 Vishay 18 1 D5 19 2 D6 D7 60 V, 60 A, Dual Schottky, TO-220AB M6060C-E3/45 Vishay 600 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 UF4005-E3 Vishay BAS16HT1G ON Semi STPS1045B-TR ST UF4001-E3 Vishay 1N5404 Vishay TRK-24 Kang Tang Hardware 64900001039 Wickmann 021706.3HXP Littlefuse CT40-5 ITW Chemtronics 20 2 D8 D9 21 1 D10 22 1 D11 23 1 D12 24 1 D13 25 1 ESIP CLIP1 26 1 F1 27 1 F2 28 1 29 2 30 2 31 2 32 1 GREASE1 HEATSINK BRACKET RIGHT1 HEATSINK BRACKET RIGHT2 HEATSINK BRACKET3 HEATSINK BRACKET4 75 V, 200 mA, Rectifier, SOD323 45 V, 10 A, Schottky Low Drop, SMD, DPAK 50 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 OBS non RoHS use 15-00796-00. 400 V, 3 A, Recitifier, DO-201AD Heatsink Hardware, Edge Clip xxN (xx lbs) 14.33 mm L x 6.35 mm W FUSEHOLDER OPEN 5 X 20 MM PC MNT 6.3 A, 250 V, Fast, 5 mm x 20 mm, Cartridge Thermal Grease, Silicone, 5 oz Tube Bracket, Heatsink, Right Custom Bracket, Heatsink, Left Custom HS PAD1 HS PAD2 HEATSINK PAD, TO-220, Sil-Pad 1000 1009-58 Bergpuist HS1 HEATSINK, RDK249-Diode-Hsink, Alum 5052, 3.00" L x 1.650" W x 0.187" Thk 61-00041-00 Custom Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 33 1 HS2 34 1 J1 35 1 J1_OPTIO 36 1 J2 37 1 J3 38 1 J4 39 1 JP1 40 3 41 HEATSINK, RDK249-eSIP-Hsink, Alum 5052, 3.00" L x 1.650" W x 0.125" Thk 2 Position (1 x 2) header, 10.16 mm (0.400) pitch, Vertical 2 Position (1 x 2) header, 10.16 mm (0.400) pitch, Vertical 2 Position (1 x 2) header, 5 mm (0.196) pitch, Vertical CONN HEADER 3POS (1x3).156 VERT TIN 2 Position (1 x 2) header, 0.1 pitch, Vertical 61-00042-00 Custom 1706785 Phoenix Contact 39910-0102 Molex 1715022 Phoenix Contact 26-64-4030 Molex 22-23-2021 Molex Wire Jumper, Insulated, 22 AWG, 0.2 in C2004-12-02 Gen Cable JP2 JP3 JP4 Wire Jumper, Insulated, 22 AWG, 0.3 in C2004-12-02 Gen Cable 5 JP5 JP6 JP7 JP8 JP9 Wire Jumper, Insulated, 22 AWG, 0.5 in C2004-12-02 Gen Cable 42 2 JP10 JP11 Wire Jumper, Insulated, 22 AWG, 0.7 in C2004-12-02 Gen Cable 43 1 JP12 Wire Jumper, Insulated, 22 AWG, 0.8 in 44 1 JP13 0 R, 5%, 1/10 W, Thick Film, 0603 45 1 L1 32 H,xA, Power Iron Toroid, 8P 46 1 L2 2.2 H, 6.0 A 47 4 POSTCRKT_BRD_632_HEX1-4 48 1 Q1 NPN, Small Signal BJT, GP SS, 40 V, 0.6 A, SOT-23 49 1 R1 2.2 , 5%, 1 W, Metal Film, Fusible 50 1 R2 51 1 R3 52 2 R4 R29 53 3 R5 R7 R8 54 1 R6 55 1 56 1 57 1 R11 43.2 k, 1%, 1/16 W, Thick Film, 0603 58 2 R12 R19 59 4 R13 R18 R35 R36 1.33 M, 1%, 1/4 W, Thick Film, 1206 MCR18EZHF1334 Rohm 60 1 R14 2 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ202V Panasonic 61 1 R15 750 , 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF7500V Panasonic 62 1 R16 7.5 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF7501V Panasonic 63 1 R17 820 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ821V Panasonic 64 2 R20 R22 4.7 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ472V Panasonic 65 1 R21 2 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2001V Panasonic 66 1 R23 1 k, 5%, 1/4 W, Carbon Film 67 1 R24 68 1 R25 69 1 70 1 71 72 C2004-12-02 Gen Cable ERJ-3GEY0R00V Panasonic SNX-R1533 Santronics USA RFB0807-2R2L Coilcraft 561-0375A Eagle Hardware MMBT4401LT1G On Semi NFR0100002208JR500 Vishay 470 , 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ471V Panasonic 100 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ101V Panasonic 150 , 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ151V Panasonic 4.7 , 5%, 1/2 W, Carbon Film CFR-50JB-4R7 Yageo 100 , 5%, 1/2 W, Carbon Film CFR-50JB-100R Yageo R9 15 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ153V Panasonic R10 221 , 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2210V Panasonic ERJ-3EKF4322V Panasonic 271-1.33M/REEL-RC Xicon Post, Circuit Board, Female, Hex, 6-32, snap, 0.375L, Nylon 1.33 M, 1%, 1/4 W, Metal Film CFR-25JB-1K0 Yageo 3.92 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF3921V Panasonic 232 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2323V Panasonic R26 200 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ201V Panasonic R27 280 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2803V Panasonic 1 R28 100 , 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ101V Panasonic 2 R30 R33 1 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ102V Panasonic Page 13 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 73 2 R31 R34 74 1 R32 4.75 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF4751V Panasonic 4.7 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ472V Panasonic 75 4 RIVET1 RIVET2 RIVET3 RIVET4 76 4 RIVET5 RIVET6 RIVET7 RIVET8 77 1 SCREW1 Rivet, Al, .093 Dia x 0.187 (3/16) L, 100 Deg Countersunk, soft, 1100-F Aluminum Rivet, Al, .093 Dia x 0.250 (1/4) L, 100 Deg Countersunk, soft, 1100-F Aluminum SCREW MACHINE PHIL 4-40 X 1/4 SS 78 2 SCREW2 SCREW3 SCREW MACHINE PHIL 4-40 X 5/16 SS 79 1 SW1 80 1 T1 81 1 T2 82 1 TP1 83 4 U1 U2 U3 U4 U5 U7 16-Nov-11 SLIDE MINI SPDT PC MNT AU Olander Olander PMSSS 440 0025 PH Building Fasteners PMSSS 440 0031 PH Building Fasteners 1101M2S3CBE2 ITT Ind/C&Kdiv Custom Transformer. Vertical, 14 pins Bobbin Custom Transformer, Vertical, 10 Pins Bobbin SNX-R1534 YC-3508 SNX-R1535 YW-360-02B Santronics USA Ying Chin Santronics USA Yih-Hwa Test Point, WHT,THRU-HOLE MOUNT 5012 Keystone Optocoupler, TRAN OUT 4-SMD OBS see 45-00144-00 2.495 V Shunt Regulator IC, 2%, -40 to 85C, SOT23 PC817XI1J00F Sharp LM431AIM National Semiconductor 84 2 85 1 U6 TFS762HG Power Integrations 86 1 VR1 12 V, 5%, 500 mW, DO-213AA (MELF) ZMM5242B-7 Diodes Inc 87 1 VR2 4.7 V, 5%, 500 mW, DO-213AA (MELF) ZMM5230B-7 Diodes Inc P6KE150A LittleFuse MMSZ5243BT1G ON Semi 4NSLWS Olander FWSS 004 Building Fasteners 3049 Keystone TFS762HG, ESIP16/12 88 1 VR3 150 V, 5 W, 5%, TVS, DO204AC (DO15) 89 1 VR4 13 V, 5%, 500 mW, SOD-123 90 3 WASHER 1, 2, 3 Washer, Lk, #4 SS 91 2 WASHER 4, 5 Washer FLAT #4 SS 92 2 WASHER 6, 7 Washer, Shoulder, Nylon, #4 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 7 Standby Transformer Specification 7.1 Electrical Diagram Figure 5 – Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Leakage Inductance 7.3 1 second, 60 Hz, from pins 1-5 to pins 6-10 Pins 1-2, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-2, all other windings open 3000 VAC 850 H, ±10% 2.15 MHz Min Pins 1-2, with secondary pins shorted, measured at 100 kHz, 0.4 VRMS Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: TDK EE25 part #: PC40EE25.4-Z Bobbin: EE25, Vertical, 10 pins, (5/5), Yhi Hwa part #: YW-360-02B Magnet wire: #29 AWG Magnet wire: #33 AWG Magnet wire: #20 AWG Triple Insulated Wire Tape: 3M 1298 Polyester Film, 2 mils thick, 10.8 mm wide Varnish Page 15 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 18 H Max RDR-249 5 V Standby and Single 12 V Main 7.4 16-Nov-11 Transformer Build Diagram Figure 6 – Transformer Build Diagram. 7.5 Transformer Construction Winding Preparation WD1: 1st Primary Insulation WD2: Auxiliary Insulation WD3: Secondary Insulation WD4: 2nd Primary Insulation Finish Position the bobbin on the mandrel such that the pin side is on the left side of bobbin mandrel. Winding direction is clock-wise direction Start at pin 1, wind 33 turns of wire item [3] from left to right with tight tension in one layer, at the last turn bring the wire back to the left and terminate at pin 4 2 layers of tape item [6] Start at pin 3, wind 12 quad-filar turns of wire item [4] from left to right also with tight tension in one layer, at the last turn bring the wire back to the left and terminate at pin 5 2 layers of tape item [6] Start at pin 9, 10 wind 4 bi-filar turns of wire item [5] from left to right also with tight tension in one layer, at the last turn bring the wire back to the left and terminate at pin 6, 7 2 layers of tape item [6] Start at pin 4, wind 32 turns of wire item [3] from right to left with tight tension in one layer, at the last turn bring the wire back to the right and terminate at pin 2 3 layers of tape item [6] Assemble, grind the cores to get 2.15 mH and secure with tape. Varnish [7] Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 8 Main Transformer Specification 8.1 Electrical Diagram Figure 7 – Transformer Electrical Diagram. 8.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage 8.3 1 second, 60 Hz, from pins 1-7 to pins 8-14 Pins 2-6, all other open, measured at 50 kHz, 0.4 VRMS Pins 2-6, all other open Pins 2-6, with pins 8-14 shorted, measured at 50 kHz, 0.4 VRMS 3000 VAC 23 mH, ±25% 200 kHz (Min.) 25 H (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] Description Core: TDK part #:PC40HEER35-Z Bobbin: EER35, Vertical, 14 pins, (7/7), YingChin part #: YC-3508 Magnet wire: #24 AWG Heavy Nyleze (Solderable Polyurethane-Nylon, Class 130°C Type B) Magnet wire: #31 AWG Heavy Nyleze (Solderable Polyurethane-Nylon, Class 130°C Type B) Copper Foil: 8 mils thick (see Fig. 3) Tape: 3M 1298 Polyester Film, 2 mil thick, 25.5 mm wide Tape: 3M 1298 Polyester Film, 2 mil thick, 36.0 mm wide Tape: 3M 44 Margin tape (cream), 3.0 mm wide Tape: 3M 44 Margin tape (cream), 6.0 mm wide Varnish Page 17 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 8.4 16-Nov-11 Transformer Build Diagram Figure 8 – Transformer Build Diagram. 4 x #20AWG 4 x #20AWG Copper Foil tape item[5] Outer tape item[7] 24.0mm 36.0mm 9.0mm 425.0mm 9.0mm Figure 9 – Copper Foil Preparation. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 48 16-Nov-11 8.5 RDR-249 5 V Standby and Single 12 V Main Transformer Construction Winding Preparation Margin Tape WD1: 1st Half Primary Insulation Copper Foil WD2: Secondary Insulation Margin Tape WD3: Support Insulation Margin Tape WD4: 2nd Half Primary Insulation Finish Page 19 of 48 Position the bobbin on the mandrel such that the pin side is on the left side of bobbin mandrel. Winding direction is clock-wise direction Place margin tape 6.0 mm item [9] for the left side and 3.0 mm item [8] for the right side matching with height of WD1 Start at pin 2, wind 44 turns of wire item [3] from left to right and right to left in 1 ½ layers and terminate at pin 4 2 layers of tape item [6] Prepare the copper foil as in above figure Use copper foil item [5], start at pins 13, 14, wind 7 turns with tight tension and end at pins 9, 10 2 layers of tape item [6] Place margin tape 6.0mm item [9] for the left side and 3.0mm item [8] for the right side matching with height of WD3 Start at pin 1, wind 5 turns item [4] from left to right, at the last turn bring the wire back to the left to terminate at pin 2 2 layers of tape item [6] Place margin tape 6.0 mm item [9] for the left side and 3.0 mm item [8] for the right side matching with height of WD4 Start at pin 4, wind 44 turns of wire item [3] from left to right and right to left in 1 ½ layers and terminate at pin 6 2 layers of tape item [6] Assemble and secure the cores with tape. Varnish item [7] Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 9 Main Output Inductor Specification 9.1 Electrical Diagram Figure 10 – Inductor Electrical Diagram. 9.2 Electrical Specifications Core Effective Inductance Inductance (LCM) 9.3 9.5 AL = 95 nH/N² 35.8 H ±10% Materials Item [1] [2] 9.4 Pins 1-2 measured at 100 kHz Description Toroid: Micrometals, part#: T132-52 Magnet Wire: #17 AWG, solderable double coated Winding Instructions Use 4 wires of item [2] about 100 cm long, wind 19 turns in ~2 layers firmly and in one direction. Start with FL1, FL2, FL3, FL4, end with FL5, FL6, FL7, FL8, and leave ~ ½” long. Tin all leads ~½” Inductor Illustrations Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 10 Transformer Design Spreadsheet (Note – Output current is made 4.20 A in the spreadsheet to account for load on the auxiliary output) HiperTFS_Twoswitch_Forward_092110 ; Rev.1.04; Copyright HiperTFS_092110 Two-switch Forward Power Integrations 2010 INPUT INFO OUTPUT UNIT Transformer Design Spreadsheet HiperTFS MAIN OUTPUT (TWO-SWITCH FORWARD STAGE) OUTPUT VOLTAGE AND CURRENT VMAIN 12.00 V Main output voltage IMAIN 25.00 A Main output current VOUT2 V Output2 voltage IOUT2 A Output2 current POST REGULATED OUTPUT !!!! Info. No Selection for post-regulator Post Regulator NONE Info select 'NONE' if not using post-regulator Select source of input voltage for post V_SOURCE V regulator VOUT3 0.0 V Enter postregulator output voltage IOUT3 0.0 A Enter post rehulator output current n_PR 1 Enter postregulator efficiency (Buck only) COUPLED-INDUCTOR (LOW POWER) DERIVED OUTPUT Coupled-Inductor derived (low power) output VOUT4 12.00 V voltage (typically -12 V) Coupled-Inductor derived (low power) output IOUT4 0.10 A current POUT(Main) 301.2 W Total output power (Main converter) Peak Output power(Main converter). If there POUT_PEAK(Main) 340.00 340.0 W is no peak power requirement enter value equal to continuous power Continuous output power from Standby POUT(Standby) 10.3 W power supply POUT_PEAK(Standby) 14.5 W Peak output power from Standby section POUT(System Total) 311.5 W Total system continuous output power POUT_PEAK(System Total) W Total system peak output power DC bias voltage from main transformer aux VBIAS 17.00 V winding INPUT VOLTAGE AND UV/OV Input Capacitance. To increase CMIN, CIN 269.92 uF increase T_HOLDUP T_HOLDUP 20.00 ms Holdup time Minimum input voltage to guarantee output VMIN 300 V regulation VNOM 380 V Nominal input voltage VMAX 420 V Maximum DC input voltage UV / OV / UVOV min max VUV OFF 236.0 287.9 V Minimum undervoltage On-Off threshold Maximum undervoltage Off-On threshold VUV ON 300.0 344.7 V (turn-on) VOV ON 480.4 V Minimum overvoltage Off-On threshold Minimum overvoltage On-Off threshold (turnVOV OFF 664.5 V off) RR 4.00 M-ohm R pin resistor Line Sense resistor value (L-pin) - goal seek RL 4 4.00 M-ohm (VUV OFF) for std 1% resistor series ENTER DEVICE VARIABLES Device TFS762 Selected HiperTFS device Chosen Device TFS762 ILIMIT_MIN 3.25 A Device current limit (Minimum) ILIMIT_TYP 3.50 A Device current limit (Typical) ILIMIT_MAX 3.75 A Device current limit (Maximum) fSMIN 61500 Hz Device switching frequency (Minimum) fS 66000 Hz Device switching frequency (Typical) Page 21 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main fSMAX 70500 KI 1.0 232.0 3.25 3.05 0.448 5.28 VCLAMP k-ohms A ohms 0.45 VDS Clamp Selection Hz 1.0 R(FB) ILIMIT SELECT RDS(ON) DVNOM_GOAL 16-Nov-11 V CLAMP TO RAIL 150.00 150.00 V 570.00 V DIODE Vf SELECTION VDMAIN 0.5 V VDOUT2 0.5 V VDOUT3 VDB TRANSFORMER CORE SELECTION Core Type EER35 0.5 0.7 V V VDSOP Bobbin AE LE AL BW M P/N: P/N: cm^2 cm nH/T^2 mm 4.5 mm LG MAX 0.002 mm L 3.00 NMAIN 7.0 NS2 0.0 NBIAS 5 VOUT2 ACTUAL 0.0 V VBIAS_ACTUAL 16.3 V TRANSFORMER DESIGN PARAMETERS NP 88 BM_MAX 1791 Gauss BM PK-PK 2714 Gauss BP_MAX 2321 Gauss BP PK-PK 3516 Gauss LP MIN 20.60 mHenries IMAG 0.123 A OD_P 0.58 mm 23 AWG AWG_P DUTY CYCLE VALUES (REGULATION) DVMIN DVNOM DVMAX Main output diodes forward voltage drop Secondary output diodes forward voltage drop 3rd output diodes forward voltage drop Bias diode forward voltage drop Selected core type EER3 5 EER35_BOBBIN 1.07 9.08 2770 26.1 Core Device switching frequency (Maximum) Select Current limit factor (KI=1.0 for default ILIMIT, or select KI=0.8 or KI=0.6) Feedback Pin Resistor value Selected current limit Rds(on) at 100'C Target duty cycle at nominal input voltage (VNOM) HiperTFS average on-state Drain to Source Voltage Select either "CLAMP TO RAIL" (default) or "CLAMP TO GND" Asymmetric Clamp Voltage Maximum HiperTFS Drain voltage (at VOVOFF_MAX) 0.57 0.45 0.40 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com PC40EER35-Z BEER-35-1116CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Bobbin safety margin tape width (2 * M = Total Margin) Maximum zero gap tolerance, default 2um Transformer primary layers (split primary recommended) Main rounded turns Vout2 rounded secondary turns (Independent windings) VBias rounded turns (forward bias winding) Approximate Output2 voltage of with NS2 = 0 turns (AC stacked secondary) Approximate Forward Bias Winding Voltage at VMIN with NB = 5 turns Primary rounded turns Max positive operating flux density at minimum switching frequency Max peak-peak operating flux density at minimum switching frequency Max positive flux density at Vmax (limited by DVMAX clamp) Max peak-peak flux density at Vmax (limited by DVMAX clamp) Minimum primary magnetizing inductance (assumes LG MAX=2um) Peak magnetizing current at minimum input voltage Primary wire outer diameter Primary Wire Gauge (rounded to maximum AWG value) Duty cycle at minimum DC input voltage Duty cycle at nominal DC input voltage Duty cycle at maximum DC input voltage Page 22 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main DOVOFF MIN 0.25 Duty cycle at over-voltage DC input voltage(DOVOFF_MIN) MAXIMUM DUTY CYLE VALUES DMAX_UVOFF_MIN DMAX_VMIN DMAX_VNOM DMAX_VMAX DMAX_OVOFFMIN CURRENT WAVESHAPE PARAMETERS 0.62 0.60 0.58 0.52 0.33 Max duty cycle clamp at VUVOFF_MIN Max duty clamp cycle at VMIN Max duty clamp cycle at VNOM Max duty clamp cycle at VMAX Max duty clamp cycle at VOVOFF_MAX IP 2.39 A IP_PEAK 2.69 A IPRMS(NOM) 1.38 A Maximum peak primary current at maximum DC input voltage Peak primary current at Peak Output Power and max DC input voltage Nominal primary RMS current at nominal DC input voltage OUTPUT INDUCTOR OUTPUT PARAMETERS KDI_ACTUAL Core Type Core AE 0.27 Pow Iron T132-52(O.D)=33) Pow Iron T132-52(O.D)=33) 80.5 mm^2 LE 79.6 AL 95.0 BW 55.9 VE 6410.0 Powder cores (Sendust and Powdered Iron) Cores MUR 75.0 H 64.9 mm nH/T^2 mm mm^3 AT/cm MUR_RATIO 0.48 LMAIN_ACTUAL 16.4 uH LMAIN_0bias 34.3 uH LOUT2 0.0 uH 2919.0 402.8 Gauss Gauss BM_IND BAC_IND Turns INDUCTOR TURNS MULTIPLIER 2.7 19.0 0.0 NOUT4_INDUCTOR 12.0 Ferrite Cores LMAIN_ACTUAL LOUT2 LG Target BM BM_IND BAC_IND Turns NMAIN_INDUCUTOR NAUX_INDUCTOR N_BIAS Wire Parameters Total number of layers IRMS_MAIN IRMS_AUX AWG_MAIN OD_MAIN Page 23 of 48 N/A N/A N/A N/A N/A N/A uH uH mm Gauss Gauss Gauss N/A N/A N/A 1.06 25.0 0.0 15.0 1.5 Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Relative permiability of material Magnetic field strength Percent of permiability as compared to permiability at H = 0 AT/cm Estimated inductance of main output at full load Estimated inductance of main output with 0 DC bias Estimated inductance of auxilliary output at full load DC component of flux density AC component of flux density Multiplier factor between main number of turns in transformer and inductor (default value = 3) Main output inductor number of turns Output 2 inductor number of turns Bias output inductor number of turns (for bias or control circuit VDD supply) 2.7 NMAIN_INDUCTOR NOUT2_INDUCTOR Current ripple factor of combined Main and Output2 outputs Select core type Coupled Inductor - Core size Core Effective Cross Sectional Area Estimated inductance of main output Estimated inductance of aux output Gap length of inductor cores Target maximum flux density Estimated maximum operating flux density AC flux density Main output inductor number of turns Aux output inductor number of turns Aux output inductor number of turns A A AWG mm Total number of layers for chosen toroid RMS current through main inductor windings RMS current through aux winding Main inductor winidng wire gauge Main winding wire gauge outer diameter Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main FILAR_MAIN RDC_MAIN 2.0 4.3 AC Resistance Ratio (Main) 16-Nov-11 mohm 4.0 CMA_MAIN J_MAIN AWG_AUX OD_MAIN FILAR_AUX RDC_AUX 260.5 13.6 0.0 N/A 2.0 0.0 AC Resistance Ratio (Aux) 0.00 CMA_AUX Info CMA A/mm^2 AWG mm mohm 0.0 CMA 0.0 A/mm^2 Number of parallel strands for main output Reisstance of wire for main inductor winding Ratio of total resistance (AC + DC) to the DC resistance (using Dowell curves) Cir mils per amp for main inductor winding Current density in main inductor winding Aux winding wire gauge Auxilliary winding wire gauge outer diameter Number of parallel strands for aux output Reisstance of wire for aux inductor winding Ratio of total resistance (AC + DC) to the DC resistance (using Dowell curves) !!! Info. Low CMA may cause overheating. Verify acceptable temperature rise Current density in auxilliary winding J_AUX Estimated Power Loss PCOPPER_MAIN PCOPPER_AUX PCORE PTOTAL SECONDARY OUTPUT PARAMETERS ISFWDRMS ISFWD2RMS 2.7 0.0 2.2 4.9 W W W W Copper loss in main inductor windinig Copper loss in aux inductor winidgs Total core loss Total losses in output choke 18.99 0.00 A A Max. fwd sec. RMS current (at DVNOM) Max. fwd sec. RMS current (at DVNOM) ISCATCHRMS ISCATCH2RMS 21.16 0.00 A A Max. catch sec. RMS current (at DVNOM) Max. catch sec. RMS current (at DVNOM) IDAVMAINF 14.18 A IDAVMAINC 14.92 A IDAVOUT2F 0.00 A IDAVOUT2C 0.00 A IRMSMAIN 1.98 A IRMSOUT2 0.00 A Maximum average current, Main rectifier (single device rating) Maximum average current, Main rectifier (single device rating) Maximum average current, Main rectifier (single device rating) Maximum average current, Main rectifier (single device rating) Maximum RMS current, Main output capacitor Maximum RMS current, Out2 output capacitor % Derating VPIVMAINF 100% 45.3 V VPIVMAINC 100% 33.4 V VPIVOUT2F 100% 0.0 V VPIVOUT2C 100% 0.0 V VPIVB 100% 32.4 V HiperTFS STANDBY SECTION (FLYBACK STAGE) ENTER APPLICATION VARIABLES VACMIN 85 VACMAX 265 fL 50 VO_SB 5.00 V V Hz V IO_SB 2.00 A IO_SB_PK POUT_SB 2.90 10 W POUT_SB_TOTAL 10.32 W POUT_SB_PK 14.7 W Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Main Forward Diode peak-inverse voltage (at VDSOP) Main Catch Diode peak-inverse voltage (at VOVOFF_MAX) Output2 Forward Diode peak-inverse voltage (at VDSOP) Output2 Catch Diode peak-inverse voltage (at VOVOFF_MAX) Bias output rectifier peak-inverse voltage (at VDSOP) Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage (at continuous power) Power Supply Output Current (corresponding to peak power) Continuous Output Power Total Standby power (Includes Bias winding power) Peak Standby Output Power Page 24 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main n 0.70 Z 0.50 tC 3.00 ENTER HiperTFS STANDBY VARIABLES Select Current Limit STD ILIM_MIN ILIM_TYP ILIM_MAX R(EN) fSmin ms Standard Current Limit 0.605 0.650 0.696 280.0 124000 A A A k-ohms Hz 50.19 A^2kHz 90 V 10 V VD_SB KP 0.5 0.71 V KP_TRANSIENT 0.36 ENTER BIAS WINDING VARIABLES VB IB PB VDB NB VZOV UVLO VARIABLES 16.00 20.00 0.32 0.70 9.11 22.00 V mA W V RLS 4.00 M-Ohms I^2fmin VOR 90.00 VDS V_UV_ACTUAL 102 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE25 EE25 EE25 Core EE25_BOBBIN Bobbin AE 0.404 LE 7.34 AL 1420 BW 10.2 M 0 L NS_SB DC INPUT VOLTAGE PARAMETERS VMIN_SB VMAX_SB CURRENT WAVEFORM SHAPE PARAMETERS 2 3 115.65 374.77 V V P/N: P/N: cm^2 cm nH/T^2 mm mm Bias Winding Voltage Bias winding Load current Bias winidng power Bias Winding Diode Forward Voltage Drop Bias Winding Number of Turns Over Voltage Protection zener diode voltage. Line sense resistor (from Main converter section) Typical DC start-up voltage Enter Transformer Core PC40EE25-Z EE25_BOBBIN 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 Duty Ratio at full load, minimum primary inductance and minimum input voltage Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current 0.46 IAVG IP_SB IR_SB IRMS_SB TRANSFORMER PRIMARY DESIGN PARAMETERS 0.20 0.60 0.43 0.32 A A A A 841.65 uH Page 25 of 48 Enter "LOW" for low current limit, "RED" for reduced current limit (sealed adapters), "STD" for standard current limit or "INC" for increased current limit (peak or higher power applications) Minimum Current Limit Typical Current Limit Maximum Current Limit Enable pin resistor Minimum Device Switching Frequency I^2f (product of current limit squared and frequency is trimmed for tighter tolerance) Reflected Output Voltage (VOR < 135 V Recommended) HiperTFS Standby On State Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (KP < 6) Transient Ripple to Peak Current Ratio. Ensure KP_TRANSIENT > 0.25 V V DMAX_SB LP_SB Efficiency Estimate at output terminals. Under 0.7 if no better data available Z Factor. Ratio of secondary side losses to the total losses in the power supply. Use 0.5 if no better data available Bridge Rectifier Conduction Time Estimate Typical Primary Inductance. +/- 10% to ensure a minimum primary inductance of 765 uH Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 LP_TOLERANCE NP_SB ALG 10 49 349 % nH/T^2 BM 2952 Gauss BAC 1050 Gauss ur LG BWE 2053 0.11 20.4 mm mm OD 0.42 mm INS 0.06 mm DIA 0.35 mm AWG 28 AWG CM 161 Cmils 506 Cmils/Amp CMA Info TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP 9.89 ISRMS 5.65 IRIPPLE 5.29 CMS A A A 1131 Cmils 19 AWG VDRAIN 584 V PIVS 28 V AWGS Primary inductance tolerance Primary Winding Number of Turns Gapped Core Effective Inductance Maximum Operating Flux Density, BM<3000 is recommended 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 Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils CAN DECREASE CMA < 500 (decrease L(primary layers),increase NS,use smaller Core) Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) VOLTAGE STRESS PARAMETERS Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Maximum Drain Voltage Estimate (Assumes 20% zener clamp tolerance and an additional 10% temperature tolerance) Output Rectifier Maximum Peak Inverse Voltage Page 26 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 11 Performance Data All measurements are performed at the PCB connector at room temperature and 380 VDC input. For standby measurements, DC input voltage vas adjusted to match the equivalent AC voltage. 11.1 Main and Standby Efficiency 92 91 Efficiency (%) 90 89 88 87 86 85 84 0 10 20 30 40 50 60 70 80 90 Output Power Level (%) Figure 11 – Main and Standby Efficiency [%], Room Temperature, Forced Cooling. Page 27 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 100 RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 11.2 Full Power Standby Efficiency vs. Equivalent AC Input Voltage 82.6 82.4 82.2 Efficiency (%) 82.0 81.8 81.6 81.4 81.2 81.0 80.8 85 100 115 130 145 160 175 190 205 220 235 250 265 280 Equivalent AC Input Voltage (V) Figure 12 – Full Power Standby Efficiency [%] vs. AC Input Voltage [V] at Room Temperature Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 11.3 Standby Efficiency vs. Output Power 82 Standby Efficiency (%) 80 78 76 Efficiency for 90 VAC Efficiency for 115 VAC 74 Efficiency for 230 VAC Efficiency for 265 VAC 72 0 10 20 30 40 50 60 70 80 90 Standby Output Power (%) Figure 13 – Standby Efficiency [%], at Room Temperature and Equivalent AC Input Voltage. Page 29 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 100 RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 11.4 Standby Only No-Load Input Power 180 160 Input Power (mW) 140 120 100 80 60 85 100 115 130 145 160 175 190 205 220 235 250 265 280 Equivalent AC Input Voltage (V) Figure 14 – Input Power [mW] vs. Input Line Voltage [V], for Zero Standby Load at Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 11.5 Main and Standby Voltage Regulation 11.5.1 Main Load Regulation 12.073 Main Regulation 12.072 Main Output Voltage (V) 12.071 12.070 12.069 12.068 12.067 12.066 12.065 12.064 0.0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0 Main Output Current (A) Figure 15 – Main Load Regulation, at Room Temperature and 380 VDC Input Voltage. Page 31 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 27.5 RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 11.5.2 Standby Load Regulation at Equivalent AC Input Voltages 4.98 Regulation at 90 VAC Regulation at 115 VAC Standby Output Voltage (V) 4.97 Regulation at 230 VAC Regulation at 265 VAC 4.96 4.95 4.94 4.93 4.92 0.0 0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.0 2.3 2.5 2.8 3.0 Standby Output Current (A) Figure 16 – Standby Load Regulation, at Room Temperature and Equivalent AC Input Voltage. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 11.5.3 Standby Line Regulation at Full Power 4.938 Standby Output Voltage (V) 4.936 4.933 4.931 4.928 4.926 4.923 85 100 115 130 145 160 175 190 205 220 235 250 Equivalent AC Input Voltage (V) Figure 17 – Line Regulation, at Room Temperature, Full Load. Page 33 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 265 280 RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 12 Thermal Performance Full output power operation at room temperature is allowed only for operation time under 10 minutes. It is required to provide forced air cooling for operation at full power for more than 10 minutes or for over-power tests. Figure 18 – HiperTFS Device Temperature. Figure 19 – Board Thermal Image. . In case of power components replacement it is important to insure a clean and smooth surfaces for heat-sink mechanical assembly with thermal conductive grease between any surface in contact, even for the isolation pad. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 13 Waveforms 13.1 Main Drain Voltage and Current, Normal Operation, Full Power Figure 20 – Input Voltage: 380 VDC Upper: Main Upper MOSFET (Red) VSOURCE, 100 V / div. Upper: Main Lower MOSFET (Gold) VDRAIN, 100 V / div. Lower: Main IDRAIN, 500 mA, 10 s / div. Page 35 of 48 Figure 21 – Input Voltage: 380 VDC Upper: Main Upper MOSFET (Red) VSOURCE, 100 V / div. Upper: Main Lower MOSFET (Gold) VDRAIN, 100 V / div. Lower: Main IDRAIN, 500 mA, 2 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 13.2 Standby Drain Voltage and Current, Normal Operation, Full Power Figure 22 – Input Voltage: 127 VDC Upper: Standby VDRAIN, 50 V / div. Lower: Standby IDRAIN, 120 mA, 1 s / div. Figure 24 – Input Voltage: 127 VDC Standby VDRAIN, 50 V / div., 10 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 23 – Input Voltage: 380 VDC Upper: Standby VDRAIN, 100 V / div. Lower: Standby IDRAIN, 100 mA, 1 s / div. Figure 25 – 380 VDC Standby VDRAIN, 100 V / div., 10 s / div. Page 36 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 13.3 Standby Drain Current and Output Voltage Start-Up Profile Figure 26 – Full Load: 127 VDC Input Voltage. Upper: VSTBY, 1 V / div. Lower: Standby IDRAIN, 200 mA, 2 ms / div. Figure 27 – Full Load: 380 VDC Input Voltage. Upper: VSTBY, 1V / div. Lower: Standby IDRAIN, 200 mA, 2 ms / div. Figure 28 – No-load at 127 VDC Input Voltage Upper: VSTBY, 1 V / div. Lower: Standby IDRAIN, 200 mA, 5 ms / div. Figure 29 – No-load at 380 VDC Input Voltage Upper: VSTBY, 1 V / div. Lower: Standby IDRAIN, 200 mA, 5 ms / div. Page 37 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 13.4 Main Drain Current, and Main and Standby Output Voltage Start-Up Profile Figure 30 – No-load: 380 VDC Input Voltage. Upper (Red): VSTBY, 1 V / div. Upper (Yellow): VMAIN, 2 V / div. Lower: Main IDRAIN, 750 mA, 5 ms / div. For this test the DC input voltage was applied with remote-ON/OFF switch in ON position. 13.5 Main Output Voltage Remote-ON Start-Up Profile Figure 31 – No-load: 380 VDC Input Voltage. Upper (Red): VSTBY, 1 V / div. Upper (Yellow): VMAIN, 2 V / div. Lower: Main IDRAIN, 750 mA, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 38 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 13.6 Main or Standby OV Shutdown In order to activate the Standby or Main Overvoltage Protection Circuit for testing purpose, the recommended procedure is to temporarily short-circuit the input side of the respective optocouplers: U1A for the Main section or U2A for the Standby section. Without proper signal, the feedback loop will be forced to maximize the control signal and the Main or the Standby output voltage will increase all the way up to the shut-down limit. This overvoltage trigger condition will force the current into the BP pin to exceed the threshold limit and the internal HiperTFS controller to lock-out in a disabled state. For resetting the lock-out condition, the input voltage must be removed to allow the voltage on the BP pin to be discharged. Figure 32 – Standby OV Protection. Upper (Red): VSTBY, 1 V / div. Upper (Yellow): VMAIN, 2 V / div. Lower: Standby IDRAIN, 200 mA, 2 ms / div. Page 39 of 48 Figure 33 – Main OV Protection. Upper (Red): VSTBY, 1 V / div. Upper (Yellow): VMAIN, 2 V / div. Lower: Main IDRAIN, 750 mA, 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 13.7 Full Power Hold-Up Time Figure 34 – Maximum Hold-Up Time = 22.3 ms Upper (Yellow): VMAIN, 2 V / div. Upper (Red): VSTBY, 1 V / div. Lower: Input VDC, 60 V, 5 ms / div. After turning OFF the input voltage, the full output power Hold-Up Time from 385 VDC down to 300 VDC is 20.8 ms. Maximum Hold-Up time (before 12 V Main output losing regulation, starting from 385 VDC input) is 22.3 ms. 13.8 Standby Auto-Restart Figure 35 – Maximum Hold-Up Time = 22.3 ms Upper: Standby VDRAIN, 100 V / div. Lower: Standby IDRAIN, 100 mA, 1 s / div. Overloading the standby output with 6 A for 380 VDC input shows repeated restart attempts every 2.3 s followed by a quick shutdown. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 40 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 13.9 Main and Standby Full Power Output Short-Circuit For short-circuit testing the recommended procedure is to use MOSFETs like IXYS IXFN180N25T or equivalent devices with high current capability connected to both Main and Standby outputs. In Short-Circuit mode only the output connectors and cable wires will have any significant resistivity. The unit will withstand short-circuit conditions without any permanent damage, and the outputs will go back to normal after the fault condition is removed. The Standby controller will try a restart cycle any time when the restart conditions are satisfied. Figure 36 – Standby Output Short-Circuit. Upper: VSTBY, 1 V / div. Lower: Standby IDRAIN, 200 mA, 50 s / div. Figure 38 – Main Output Short-Circuit. Upper: VMAIN, 2 V / div. Lower: Main IDRAIN, 750 mA, 50 Page 41 of 48 s / div. Figure 37 – Standby Output Short-Circuit. Upper: VSTBY, 1 V / div. Lower: Standby IDRAIN, 200 mA, 100 ms / div. Figure 39 – Main Output Short-Circuit. Upper: VMAIN, 2 V / div. Lower: Main IDRAIN, 750 mA, 100 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 13.10 Main Remote-ON/OFF Figure 40 – Main Remote-ON: 385 VDC = 28.5 ms. Upper: VMAIN, 2 V / div. Lower: Remote-ON, 1 V, 5 ms / div. Figure 41 – Main Remote-OFF: 385 VDC = 265 s. Upper: VMAIN, 2 V / div. Lower: Remote-OFF, 1 V, 5 ms / div. Main Remote-ON start-up time is measured between Remote-ON/OFF signal going in ON state and Main 12 V output reaching 11.5 V, and it is 28.5 ms. Main Remote-OFF shut-down time is measured from Remote-ON/OFF signal going in OFF state and Main 12 V output going down to 11.5 V, and it is 265 s. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 42 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 13.11 Output Ripple Measurements 13.11.1 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 5125BA 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) 1.0F/50V 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 42 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 43 – Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified for ripple measurement, and two parallel decoupling capacitors added) Page 43 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 13.11.2 16-Nov-11 Measurement Results Figure 44 – Standby Output Ripple: 380 VDC VSTBY, 20 mV / div., 5 s / div. (Full Load) Figure 45 – Standby Output Ripple: 380 VDC. VSTBY, 20 mV / div., 2 ms / div. (Full Load) Figure 46 – Main Output Ripple: 380 VDC VMAIN, 20 mV / div., 5 s / div. (Full Load) Figure 47 – Main Output Ripple: 380 VDC VMAIN, 20 mV / div., 2 ms / div. (Full Load) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 44 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 13.12 Main and Standby Load Transient Response The waveform shows the instantaneous output voltage for 33% to 66% step load change. The voltage step change is under 50 mV for Standby output and under 150 mV for Main output. For the Standby test the Main output was off, for the Main test the Standby output was loaded at 50%. Figure 48 – Standby Step Load: 380 VDC Upper: VSTBY, 20 mV / div. Lower: Standby IOUT, 300 mA, 2ms / div. Page 45 of 48 Figure 49 – Main Step Load: 380 VDC Upper: VMAIN, 50 mV / div. Lower: Main IOUT, 2.5 A, 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 14 Design Notes: 1. Pay extra attention when mounting the TFS762HG and the eSIP clip. TFS762HG must be placed flush with the PCB, as close as possible There must be at least 2 mm clearance between clip and TFS762HG edge to avoid short-circuit from exposed metallic ends to mounting clip. 2. For convenience, two LED footprints are provided for optional visual control. All no-load tests must be completed without LEDs. 3. J1_OPTIO it is provided at schematic and BOM level as an alternative option only. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 46 of 48 16-Nov-11 RDR-249 5 V Standby and Single 12 V Main 15 Revision History Date 09-Nov-10 16-Nov-11 Page 47 of 48 Author AN KM Revision 1.0 1.1 Description and changes Initial Release Updated BOM and Schematic Reviewed Apps & Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-249 5 V Standby and Single 12 V Main 16-Nov-11 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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