设计范例报告 标题 使用HiperPFSTM-2 PFS7328H和HiperLCSTM LCS703HG设计的255 W 80 PLUS白金级 PC电源 规格 90 VAC – 265 VAC输入； 12 V、19.71 A和12 V、1.5 A输出 应用 PC电源 作者 应用工程部 文档编号 DER-385 日期 2014年1月22日 修订版本 2.1 特色概述 • 使用HiperPFS-2系列IC PFS7328H设计的集成PFC级 • 使用HiperLCS系列IC LCS703HG设计的LLC级 • 使用TinySwitchTM-III系列IC TNY279PG设计的待机电源 • CAPZeroTM (CAP004DG) IC用于对X电容放电，能实现比电阻式方案更高的效率 • 次级同步整流 • 满足80 PLUS 白金级效率要求 • 在115 VAC输入下，系统效率在20/50/100%下分别达到92.1% / 93.4% / 91.1% • 在230 VAC输入下，系统效率在20/50/100%下分别达到91.9% / 94.6% / 93.3% 专利信息 此处介绍的产品和应用（包括产品之外的变压器结构和电路）可能包含一项或多项美国及国外专利，或正在申请的 美国或国外专利。有关Power Integrations专利的完整列表，请参见www.powerint.com。Power Integrations按照在 <http://www.powerint.com/ip.htm>中所述规定，向客户授予特定专利权利的许可。 Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 目录 1 2 3 4 简介 ............................................................................................................................ 4 电源规格 ..................................................................................................................... 6 电路原理图 ................................................................................................................. 7 电路描述 ................................................................................................................... 10 4.1 输入滤波器/升压式转换器/偏置供电 ................................................................... 10 4.1.1 EMI滤波...................................................................................................... 10 4.1.2 浪涌限制 ..................................................................................................... 10 4.1.3 主PFC级 ..................................................................................................... 10 4.1.4 待机电源 ..................................................................................................... 11 4.2 LLC转换器 ......................................................................................................... 12 4.3 初级 ................................................................................................................... 12 4.4 输出同步整流 ..................................................................................................... 14 5 PCB布局 ................................................................................................................... 15 6 物料清单(BOM)......................................................................................................... 17 7 散热片组件 ............................................................................................................... 21 7.1 LLC散热片 ......................................................................................................... 21 7.1.1 LLC散热片工程图和装配 ............................................................................ 21 7.1.2 PFS散热片工程图和装配 ............................................................................ 22 7.1.3 桥式整流管散热片工程图和装配 ................................................................. 23 8 磁芯元件 ................................................................................................................... 24 8.1 PFC扼流圈(L3)规格 ........................................................................................... 24 8.1.1 电气原理图 ................................................................................................. 24 8.1.2 电气规格 ..................................................................................................... 24 8.1.3 材料 ............................................................................................................ 24 8.1.4 PFC电感总装 .............................................................................................. 24 8.2 LLC变压器(T1)规格 ........................................................................................... 25 8.2.1 电气原理图 ................................................................................................. 25 8.2.2 电气规格 ..................................................................................................... 25 8.2.3 材料 ............................................................................................................ 25 8.2.4 结构图 ........................................................................................................ 26 8.2.5 绕制说明 ..................................................................................................... 26 8.3 待机变压器(T2)规格 ........................................................................................... 27 8.3.1 电气原理图 ................................................................................................. 27 8.3.2 电气规格 ..................................................................................................... 27 8.3.3 材料 ............................................................................................................ 27 8.3.4 变压器结构图 .............................................................................................. 28 8.3.5 变压器构建说明 .......................................................................................... 28 8.4 输出电感(L4)规格 .............................................................................................. 29 8.4.1 电气原理图 ................................................................................................. 29 8.4.2 电气规格 ..................................................................................................... 29 8.4.3 材料 ............................................................................................................ 29 9 LLC转换器设计表格 .................................................................................................. 30 10 待机转换器设计表格 .............................................................................................. 37 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第2页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 11 功率因数控制器设计表格 .......................................................................................40 12 性能数据 ................................................................................................................45 12.1 系统效率 ............................................................................................................45 12.2 功率因数 ............................................................................................................46 12.3 THD ...................................................................................................................47 12.4 输出调整 ............................................................................................................48 12.4.1 线电压调整 .................................................................................................48 12.4.2 负载调整 .....................................................................................................49 13 输入电流谐波限值与EN 61000-3-2 Class D限值 ...................................................50 14 波形 .......................................................................................................................52 14.1 输入电压及电流 .................................................................................................52 14.2 LLC初级电压及电流 ...........................................................................................52 14.3 PFC开关电压和电流 - 正常工作 .........................................................................53 14.4 启动时的AC输入电流和PFC输出电压 ................................................................54 14.5 LLC启动（CR模式） .........................................................................................54 14.6 LLC电压跌落 ......................................................................................................55 14.7 LLC输出短路 ......................................................................................................56 14.8 主启动和待机启动（CR模式） ..........................................................................56 14.9 同步FET漏极和栅极电压....................................................................................57 14.10 输出纹波测量 .................................................................................................58 14.10.1 纹波测量方法 ..........................................................................................58 14.10.2 满载输出纹波结果 ...................................................................................59 14.10.3 空载纹波结果 ..........................................................................................59 14.11 主输出负载阶跃响应 .......................................................................................60 14.12 待机输出负载阶跃响应 ...................................................................................61 15 传导EMI.................................................................................................................62 15.1 EMI设置 .............................................................................................................62 15.1.1 EMI测试的电源准备 ....................................................................................62 15.1.2 EMI测试设置 ...............................................................................................63 15.2 EMI扫描 .............................................................................................................64 16 增益相位测量 .........................................................................................................66 17 附录 .......................................................................................................................67 17.1 中继电缆准备 .....................................................................................................67 17.2 PFC电感装配 .....................................................................................................68 18 版本历史 ................................................................................................................69 重要说明： 虽然本电路板的设计满足安全隔离要求，但工程原型尚未获得机构认证。因此，必须使用 隔离变压器向原型板提供AC输入，以执行所有测试。 第3页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 1 22-Jan-14 简介 本工程报告介绍的是一款在90 VAC至265 VAC输入电压范围内工作的12 V、19.71 A主转 换 器 和 12 V 、 1.5 A 待 机 转 换 器 的 PC 电 源 设 计 范 例 ， 该 电 源 还 可 用 作 使 用 Power Integrations的HiperPFS-2和HiperLCS系列器件设计的PFS功率因数级与LCS输出级的通 用评估板。 本 设 计 采 用 PFS7328H 用 于 PFC 前 端 ， 采 用 TNY279PG 用 于 隔 离 反 激 式 待 机 电 源 。 LCS703HG IC用于LLC输出级。 Figure 1 – DER-385 Photograph, Top View. Figure 2 – DER-385 Photograph, Bottom View. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第4页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 Figure 3 – DER-385 Input Connector. 注：C1、C2和C3置于输入连接器上。 本报告中的电路在90 VAC至230 VAC的输入电压范围内以及在100%负载、50%负载和 20%负载下均可实现>0.9的功率因数。 第5页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 2 电源规格 下表所列为设计的最低可接受性能。实际性能可参考测量结果部分。 说明 输入 电压 频率 符号 VIN fLINE 最小值 典型值 最大值 90 47 50/60 THD PF 0.97 输出电压 VM 11.4 输出纹波 VRIPPLE(M) 功率因数 265 63 <15 <15 单位 备注 VAC Hz % % 三线输入 满载，115 VAC 满载，230 VAC 满载，230 VAC 主转换器输出 12 12.6 V 12VDC ±5% 120 mV P-P 20 MHz带宽 IM 0.00 19.71 N/A A 电源在空载条件下受到保护 输出电压 VSB 11.4 12 12.6 V 12 VDC ±5% 输出纹波 VRIPPLE(SB) 120 mV P-P 20 MHz带宽 输出电流 ISB N/A A 电源在空载条件下受到保护 输出电流 待机转换器输出 0.00 1.5 总输出功率 连续输出功率 效率 POUT 满载下的整体系统效率 ηsys 255 W 91 93 % 在115 VAC、满载条件下测得 在230 VAC、满载条件下测得 环境 传导EMI 满足CISPR22 / EN55022 Class B要求 谐波电流 环境温度 EN 61000-3-2 Class D TAMB 0 50 o C 参见热结果部分的具体条件 注：本电源要求为50%以上的负载提供强制风冷。 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第6页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 3 电路原理图 Figure 4 – Schematic DER-385 PC Platinum Power Supply Application Circuit - Input Filter, Bridge Rectifier Section and PFS Section. 第7页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 Figure 5 – Schematic DER-385 PC Platinum Power Supply Application Circuit – Main Converter Section. Figure 6 – Schematic DER-385 PC Platinum Power Supply Application Circuit – Standby Section. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第8页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 Figure 7 – Schematic DER-385 PC Platinum Power Supply Application Circuit – Sync. Rectifier Section. Note: * marked components are optional. 第9页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 4 电路描述 图4、5和6中的电路采用了Power Integrations的PFS7328H、LCS703HG、TNY279PG和 CAP004DG（可选）器件，这些电路都属于为PC电源供电的12 V、255 W带功率因数校正 的LLC电源。 4.1 输入滤波器/升压式转换器/偏置供电 图4和图5中的电路原理图显示的是输入EMI滤波器和PFC级。功率因数矫正器采用集成了 功率MOSFET和二极管的PFS7328H PFC控制器。图6中电路原理图显示的是偏置供电， 待机电源是使用TNY279PG的隔离反激式电源。CAP004DG仅在AC输入电压不存在时对 X电容C3和C6放电，从而消除电阻R1和R2的静态功耗。 4.1.1 EMI滤波 保险丝F1对电路提供过流保护，在故障发生时将电路与AC电源隔离。二极管桥堆BR1对 AC输入进行整流。电容C1、C2、C3、C4、C5、C6和C7与电感L1和L2共同形成EMI滤波 器，用于衰减共模和差模传导噪声。薄膜电容C9提供输入去耦电荷存储，以减小开关频率 及其谐波下的输入纹波电流。 电阻R1、R2和CAPZero IC U1用来在电路断开输入电压后对EMI滤波电容进行放电，同时 使工作期间的功耗为零。 金属氧化物压敏电阻(MOV) RV1通过有效箝位电源的输入电压来实现对电路的输入浪涌 保护。 U2和U4的初级散热片连接到初级回路，以消除散热片作为辐射/电容耦合噪声的来源。 4.1.2 浪涌限制 热敏电阻RT1用于限制浪涌。该电阻在正常工作期间被继电器RL1短路，并由主输出电压 激活提供栅极控制，这样效率会提高约1% - 1.5%。 继电器RL1在主输出供电达到稳压时导通，从而使热敏电阻RT1短路。 4.1.3 主PFC级 升压转换器级由升压电感L3和PFS7328H IC U2构成。该转换器级作为PFC升压转换器进 行工作，因此可维持电源的正弦输入电流，同时稳定输出DC电压。 启动时，二极管D2为输出电容C12提供一个浪涌电流通路，这样可旁路开关电感L3和PFS 器件U2，从而防止在开关电感和输出电容之间出现共振干扰。 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第10页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 电容C10为RTN提供一个较短的高频率返回回路，以提高EMI性能，并且能在关断后降低 U2 MOSFET漏极电压过冲。电容C15为U2 VCC引脚提供去耦和旁路。 IC U2利用电阻R3、R4和R5对电源的输入电压进行检测。电容C13为IC U2的V引脚提供 旁路。 输出电压电阻性分压器网络由R7、R8、R9和R13组成，它可提供与输出电压成比例的缩 放电压，用作对控制器IC U2的反馈。电容C11向U2 FB引脚提供快速的dv/dt反馈，以便 PFC电阻作出快速的下冲和过冲响应。 电阻R12和电容C17提供控制环路主极点。C18、C16和R14用来衰减高频率噪声。 电阻R11与C17串联，提供低频率补偿零点，而二极管D3可防止C17意外短路造成的误 操作。 4.1.4 待机电源 元件U7、T2、D11、C45、D8和VR1形成一个简单的隔离反激式电源，提供待机功率。 变压器T2采用EF20磁芯设计而成。 通 过 开 / 关 控 制 ， U7 可 跳 过 开 关 周 期 ， 并 可 根 据 馈 入 到 其 ENABLE/UNDERVOLTAGE (EN/UV)引脚的电流对输出电压进行调节。就在每个开关周期之前对EN/UV引脚电流进行 采样，以确定是否应使能或禁止该开关周期。如果EN/UV引脚电流<115 μA，则开始下一 开关周期，并在流经MOSFET的电流达到内部流限阈值时终止。为了平均分配开关周期， 从而防止群脉冲，EN/UV引脚阈值电流会根据上一周期的状态被调制在115 μA和60 μA之 间。控制器内的状态机将调节功率MOSFET流限阈值调节到四个水平值中的一个，具体取 决于电源所要求的负载。随着电源负载的下降，流限阈值也将减小。这可以确保有效开关 频率始终保持在音频范围之上，直至变压器磁通量变低。如果变压器采用标准的生产浸漆 工艺，就可以基本消除音频噪声。 二极管D11对T2的输出进行整流。C45使用较低的ESR电容可以降低输出电压纹波。后级 滤波器由L5和C46组成，用来衰减高频开关噪声。 主输出和待机输出使用D12和D13进行逻辑或组合，以便提高整体系统效率。 电源的输出电压稳压设定点由电阻R53和R54以及U8参考电压设定。电阻R50限制负载瞬 态期间的最大电流。当输出电压高于设定点时，U6中的LED将开始正向偏置。在初级侧， U6的光敏晶体管导通并将电流从U7的EN/UV引脚拉出。就在每个周期开始前，控制器会 检测EN/UV引脚电流。如果从EN/UV引脚流出的电流大于115 μA，将禁止该开关周期。 随着开关周期的使能和禁止，输出电压维持在非常接近稳压设定点的水平。 第11页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 4.2 22-Jan-14 LLC转换器 图5所示为一款使用LCS703HG设计的12 V、237 W LLC DC-DC转换器的电路原理图。 4.3 初级 集成电路U4集成了LLC谐振半桥(HB)转换器所需的控制电路、驱动器和输出MOSFET。 U4的HB输出经由隔直电容/谐振电容(C24)驱动输出变压器T1。该电容的额定值应根据工 作纹波电流来确定，并能够耐受故障条件下的高电压。 变压器T1的设计漏感为115 μH。T1与谐振电容C24根据以下公式共同将初级串联谐振频率 设定为约90 kHz： fR = 1 6.28 LL × C R ƒR是串联谐振频率（单位Hz），LL是变压器漏感（单位H），CR是谐振电容(C24)的值 （单位F）。 变压器匝数比已通过调整初级绕组圈数进行设定，以使额定输入电压和满载下的工作频率 接近但略小于前面所介绍的谐振频率。 测试发现，90 kHz的工作频率是在变压器尺寸、输出滤波器电容（可使用陶瓷电容）和效 率之间折中后的最佳频率点。 所选取的次级绕组圈数在磁芯和铜损耗之间达到了良好的平衡。AWG #40利兹线用于初级 绕组，AWG #38利兹线用于次级绕组，这一组合可在工作频率(~90 kHz)下提供高效率。 每种线规利兹线的股数的选择是在绕组适配性与铜损耗之间进行折中的结果。 所选用的磁芯材料是PC95（TDK产品）。这种材料能提供更好（低损耗）的性能。 元件D4、R19和C23形成自举电路，为U4的内部上管驱动器供电。 元件C20和R20对+12 V输入提供滤波和旁路，该输入是U4的VCC电源。注：VCC电压>15 V 时可损坏U4。 分压器R15、R16、R17和R18用于设定U4的高压导通、关断和过压阈值。当输入过压关 断点为473 VDC时，所选取的分压器值可将LLC导通点设定在360 VDC，将关断点设定在 285 VDC。 电容C22是+380 V的高频率旁路电容，在U4的D与S1/S2引脚之间以短走线连接。 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第12页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 电容C30与C24一起形成分流器，用于对一部分初级电流进行采样。电阻R29可检测此电 流，所产生的信号由R28和C29进行滤波。电容C30的额定值应根据故障条件下出现的峰值 电压来确定，应采用金属膜、SL陶瓷或NPO/COG陶瓷等稳定的低损耗介质。RD-385所使 用的电容为具有“SL”温度特性的圆盘状陶瓷电容，它常用于CCFL管的驱动器。根据以下公 式，所选取的值可将1周期（快速）流限值设定在6.52 A，将7周期（慢速）流限值设定在 3.62 A： I CL = 0 .5 C 30 × R 29 C 24 + C 30 ICL 是7个周期流限值（单位A），R29是限流电阻（单位Ohms），C24和C30分别是谐振 电容和电流采样电容的值（单位nF）。对于1个周期流限值，可在上面公式中用0.9 V替代 0.5 V。 电阻R28设定为最小建议值220 Ω。C29的设定值为1 nF，以避免因噪声导致的误触发， 并该值并不足以影响上面计算出的流限设定值。这些元件应靠近IS引脚放置，以便发挥最 大效用。IS引脚可承受负向电流，因此电流检测不需要采用复杂的整流方案。 R23和R27形成戴维宁等效电路，将死区时间设定为625 ns，并将U4的最大工作频率设定 为434 kHz。U4的FMAX输入由C27进行滤波。R23和R27相结合还可为U4选择脉冲串模式 “2”。这样可将脉冲串阈值频率的下限和上限分别设定为160 kHz和187 kHz。 反馈引脚具有每μA流入反馈引脚的电流的频率为2.6 kHz的近似特性。随着注入反馈引脚 的电流的增大，U4的工作频率就越高，从而降低输出电压。R21与R22相串联可将U9的最 小工作频率设定为62 kHz左右。该设定值通常低于在满载和最低大容量电容电压下实现稳 压所需的频率。电阻R21被C19旁路以在启动时提供输出软启动，工作方式是：在反馈环 路开环时，最初允许更高的电流流入反馈引脚。这可使开关频率在开始时较高，随后在输 出电压达到稳压后降低。电阻R21的设定值通常与R23相同，以便软启动时的初始频率等 于R23所设定的最大开关频率。如果R22的值小于该值，它将会在施加输入电压后开关开 始之前造成延迟。 光耦器U3经由R24来驱动U4的反馈引脚，R24可限制流入反馈引脚的最大光耦器电流。 电容C28用于对反馈引脚进行滤波。电阻R25可加载光耦器输出，以强制它以相对较高的 静态电流进行工作，从而提高其增益。电阻R24和R25还可改善强信号阶跃响应和脉冲串 模式输出纹波。二极管D5可将R25从FMAX/软启动网络隔离。 第13页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 4.4 22-Jan-14 输出同步整流 变压器T1的输出通过使用同步整流控制器U9、MOSFET Q2和Q3、二极管D6和D7以及电 容C31和C32进行整流和滤波。这些电容都是有机聚合物电容，根据输出纹波电流额定值 仔细选出。选用同步整流是为了满足80 PLUS白金级效率要求。本设计优选了MOSFET Q2和Q3，可实现更大的MOSFET导通期间和更高的效率。在布置同步整流器控制器及其 相关元件时必须极其谨慎。本设计选取了-12 mV（而非-25 mV）的漏极电压检测关断阈 值，可在给定负载下实现更大的MOSFET导通期间。二极管D6和D7用来进一步提高效 率，实现方法是在MOSFET关断时避免MOSFET体二极管导通。L4和C33提供额外的输出 滤波。 电阻R37、R38与U5参考电压相配合，可设定电源的输出电压。误差放大器U5经由R33对 反馈光耦器U3提供驱动。元件C34、C26和C37、R33、R32、R36和R26可决定电源的增 益相位特性。这些选取的值可在额定和极端负载/不同输入电压下提供稳定的工作。当光耦 器U3的LED中无电流经过时，电阻R34允许最小要求工作电流流入U3。元件C35与R35形 成软结束网络，用来消除导通时的输出过冲。 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第14页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 5 PCB布局 Figure 8 – Printed Circuit Layout – Main Board, Top Side. Figure 9 – Printed Circuit Layout – Main Board, Bottom Side. 第15页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 Figure 10 – Printed Circuit Layout – Daughter Board, Top Side. Figure 11 – Printed Circuit Layout – Daughter Board, Bottom Side. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第16页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 6 物料清单(BOM) Item Qty Ref Des Description Mfg Part Number Mfg GBU8K-BP Micro Commercial CD90-B2GA331KYNS TDK Main Board BOM 1 1 BR1 2 2 C1 C2 3 1 C3 4 2 C4 C5 800 V, 8 A, Bridge Rectifier, GBU Case 330 pF, 250 VAC, Film, X1Y1 220 nF, 275VAC, Film, X2 2.2 nF, Ceramic, Y1 5 1 C6 150 nF, 275 VAC, Film, X2 6 1 C7 1.5 nF, Ceramic, Y1 7 2 C8 C41 8 1 C9 100 nF 50 V, Ceramic, X7R, 0603 R46KI322050M2K Kemet 440LD22-R Vishay LE154-M OKAYA 440LD15-R Vishay C1608X7R1H104K TDK 680 nF, 450 VDC, Disc Ceramic ECQ-E2W684KH Panasonic VJ1812Y103KXGAT Vishay 9 1 C10 10 nF, 1 kV, Ceramic, X7R, 1812 10 1 C11 47 nF, 200 V, Ceramic, X7R, 1206 11 1 C12 220 μF, 450 V, Electrolytic, (22 x 45) 12 3 C13 C16 C28 13 1 C14 14 2 15 12062C473KAT2A AVX ESMQ451VSN221MP45S United Chemi-con 22 nF 50 V, Ceramic, X7R, 0603 C1608X7R1H223K TDK 1000 pF, 100 V, Ceramic, COG, 0603 C1608C0G2A102J TDK C15 C35 3.3 μF, 25 V, Ceramic, X7R, 0805 C2012X7R1E335K TDK 1 C17 2.2 μF, 25 V, Ceramic, X7R, 0805 C2012X7R1E225M TDK 16 2 C18 C48 CC0603KRX7R8BB473 Yago 17 1 C19 C1608X7R1C334K080AC TDK 18 2 C20 C21 19 1 C22 20 1 21 1 22 2 C25 C27 23 1 C26 24 1 25 47 nF 25 V, Ceramic, X7R, 0603 330 nF, 16 V, Ceramic, X7R, 0603 1 μF, 25 V, Ceramic, X5R, 0805 C2012X5R1E105K TDK 22 nF, 630 V, Ceramic, X7R, 1210 GRM32QR72J223KW01L Murata C23 220 nF 50 V, Ceramic, X7R, 0603 CGA3E3X7R1H224K TDK C24 27 nF, 1600 V, Film BFC238350273 Vishay 4.7 nF 50 V, Ceramic, X7R, 0603 GRM188R71H472KA01D Murata 100 nF, 25 V, Ceramic, X7R, 0805 08053C104KAT2A AVX C29 1 nF, 50 V, Ceramic, X7R, 0805 08055C102KAT2A AVX 1 C30 102R18N101JV4E Johanson Dielectrics 26 2 C31 C32 RL81C271MDN1KX Nichicon 27 1 C33 ELXZ160ELL152MJ30S Nippon Chemi-Con 28 1 C34 100 pF, 1000 V, Ceramic, NPO, 1206 270 μF, 16 V, Al Organic Polymer, Gen. Purpose, 20% 1500 μF, 16 V, Electrolytic, Low ESR, 37 mΩ, (10 x 30) 6.8 nF, 50 V, Ceramic, X7R, 0805 CC0805KRX7R9BB682 Yageo 29 1 C37 30 1 C39 31 1 32 1 33 1 C0603C103K5RACTU Kemet ELXZ250ELL331MH15D Nippon Chemi-Con C40 10 nF 50 V, Ceramic, X7R, 0603 330 μF, 25 V, Electrolytic, Low ESR, 90 mΩ, (8 x 15) 100 nF, 50 V, Ceramic, X7R, 0805 CC0805KRX7R9BB104 Yageo C42 220 pF, 50 V, Ceramic, X7R, 0805 CC0805KRX7R9BB221 Yageo C43 33 nF, 400 V, Film ECQ-E4333KF Panasonic 34 1 C44 470 pF, 250 V, Ceramic,GCM, 0805 GCM21A7U2E471JX01D Murata 35 1 C45 KMG16WV1000UF10X16 Sam Young 36 1 C46 ELXZ160ELL331MH12D Nippon Chemi-Con 37 2 D1 D3 1000 μF, 16 V, Electrolytic, (10 x 16) 330 μF, 16 V, Electrolytic, Low ESR, 120 mΩ, (8 x 12) 130 V, 5%, 250 mW, SOD-123 BAV116W-7-F Diodes, Inc. 38 1 D2 DIODE GEN PURPOSE, 800 V, 8 A ,SMC 39 1 D4 40 1 D5 41 2 D6 D7 42 1 D8 1000 V,1 A, Fast Recovery Diode, GP DO-41 FR107G-B Rectron 43 1 D9 200 V, 1 A, Fast Recovery, 150 ns, SMA RS1D-13-F Diodes, Inc. 44 1 D10 600 V, 1 A, Standard Recovery, SMA S1J-13-F Diodes, Inc. 第17页（共70页） S8KC-13 Diodes, Inc 600 V, 1 A, Ultrafast Recovery, 75 ns, SOD-123 UFM15PL-TP Micro Commercial 75 V, 0.15 A, Switching, SOD-323 BAV16WS-7-F Diodes, Inc. Diode SBR 40 V, 30 A, TO220AB SBR30A40CT Diodes, Inc. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 Diode SBR 100 V, 5 A, ITO, 220AB 22-Jan-14 45 1 D11 46 2 D12 D13 47 1 48 3 49 1 50 1 F1 GREASE1GREASE3 HEATSHRIN K1 HS1 Heat Sink, Custom, Al, 3003, 0.090" Thk Custom 51 1 HS2 Heat Sink, Custom, Al, 3003, 0.090" Thk Custom 52 1 HS3 Heat Sink, Custom, Al, 3003, 0.078" Thk 53 6 J1 J2 J9-J12 54 2 J3 J4 55 1 J5 56 1 J8 57 3 58 3 59 1 JP1 JP7 JP9 JP2 JP10 JP12 JP3 60 1 JP4 61 2 JP5 JP8 20 V, 5 A, Schottky, DO-201AD SBR10U100CTFP Diodes, Inc. SB520-E3/54 Vishay 5 A, 250 V, Slow, Long Time Lag, RST RST 5 Belfuse Thermal Grease, Silicone, 5 oz Tube CT40-5 ITW Chemtronics FIT221B-3/16 BK100 Alpha Wire Heat Shrink 3/16 IN X 4 FT BLACK PCB Terminal Hole, #18 AWG Custom N/A N/A 2 Position (1 x 2) header, 0.1 pitch, Vertical 22-23-2021 Molex 4 Position (1 x 4) header, 0.156 pitch, Vertical 26-48-1045 Molex Wire Jumper, Insulated, #24 AWG, 0.4 in C2003A-12-02 Gen Cable Wire Jumper, Insulated, #24 AWG, 0.5 in C2003A-12-02 Gen Cable Wire Jumper, Insulated, #24 AWG, 1.0 in C2003A-12-02 Gen Cable Wire Jumper, Insulated, #24 AWG, 1.2 in C2003A-12-02 Gen Cable Wire Jumper, Insulated, #24 AWG, 0.3 in C2003A-12-02 Gen Cable 2 Position (1 x 2) header, 0.1 pitch, Vertical Molex 62 1 JP6 Wire Jumper, Insulated, #24 AWG, 0.9 in C2003A-12-02 Gen Cable 63 2 JP11 JP13 Wire Jumper, Insulated, #24 AWG, 0.6 in C2003A-12-02 Gen Cable 64 3 JP14-JP16 Wire Jumper, Insulated, TFE, #22 AWG, 0.3 in 65 1 L1 9 mH, 5 A, Common Mode Choke 66 1 L2 220 μH, 3.6 A, Vertical Toroidal 2216-V-RC Bourns 67 1 L3 YC-PQ3220 Ying Chin 68 1 L4 69 1 RFB0807-2R2L Coilcraft 70 4 71 4 L5 MTG_HOLE1MTG_HOLE4 P3-P6 Bobbin, PQ32/20, Vertical, 12 pins Custom, DER-385 Main Post Filter Inductor, 500 nH 2.2 μH, 6.0 A 08-50-0113 Molex 72 1 Q1 MMBT4401LT1G Diodes, Inc. 73 2 R1 R2 74 3 75 76 C2004-12-02 Alpha T22148-902S P.I. Custom Fontaine Technologies Mounting Hole No 4 CONN TERM FEMALE #22-30 AWG TIN NPN, Small Signal BJT, GP SS, 40 V, 0.6 A, SOT-23 390 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ394V Panasonic R3 R4 R7 1.50 MΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1504V Panasonic 3 R5 R45 R46 1.00 MΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1004V Panasonic 1 R6 4.7 Ω, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ4R7V Panasonic 77 1 R8 732 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF7323V Panasonic 78 1 R9 1.60 MΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1604V Panasonic 79 1 R10 49.9 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF4992V Panasonic 80 1 R11 7.5 kΩ, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ752V Panasonic 81 1 R12 487 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF4873V Panasonic 82 1 R13 60.4 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF6042V Panasonic 83 1 R14 3 kΩ, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ302V Panasonic 84 2 R15 R16 976 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF9763V Panasonic 85 1 R17 976 kΩ, 1%, 1/4 W, Metal Film MFR-25FBF-976K Yageo 86 1 R18 20 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2002V Panasonic 87 1 R19 2.2 Ω, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ2R2V Panasonic 88 1 R20 10 Ω, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ100V Panasonic 89 1 R21 5.76 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF5761V Panasonic 90 1 R22 140 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1403V Panasonic 91 1 R23 15 kΩ, 1%, 1/4 W, Metal Film MFR-25FBF-15K0 Yageo Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第18页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 1 kΩ, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ102V Panasonic 1 R24 R34 R36 R51 R25 2.4 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ242V Panasonic 1 R26 330 Ω, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ331V Panasonic 95 1 R27 130 kΩ, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ134V Panasonic 96 1 R28 220 Ω, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ221V Panasonic 97 1 R29 37.4 Ω, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF37R4V Panasonic 98 2 R30 R31 0.002 Ω, 1%, 2 W, Thick Film, 2512 PMR100HZPFV2L00 Rohm Semi 99 1 R32 220 Ω, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ221V Panasonic 100 1 R33 2.15 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2151V Panasonic 101 1 R35 10 Ω, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ100V Panasonic 102 1 R37 38.3 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF3832V Panasonic 103 2 R38 R54 10 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1002V Panasonic 104 1 R39 1 Ω, 5%, 1/4 W, Carbon Film CFR-25JB-1R0 Yageo 105 1 R41 3.01 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF3011V Panasonic 106 1 R42 23.7 kΩ, 1%, 1/4 W, Metal Film MFR-25FBF-23K7 Yageo 107 1 R43 1.2 MΩ, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ125V Panasonic 108 2 R44 R47 MFR-25FBF-1M00 Yageo 109 1 R48 100 Ω, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ101V Panasonic 110 1 R49 10 Ω, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF10R0V Panasonic 111 1 R50 200 Ω, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF2000V Panasonic 112 1 R52 16.9 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1692V Panasonic 113 1 R53 36.5 kΩ, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF3652V Panasonic 114 1 RL1 RELAY GEN PURPOSE SPST 8 A 12 V G6RL-1A-ASI-DC12 OMRON 115 1 RT1 NTC Thermistor, 2.5 Ω, 5 A SL10 2R505 Ametherm 116 1 RTV1 RTV 670810.10ZCLR Silico RTV670810.10ZCLR GE 117 1 320 V, 23 J, 10 mm, RADIAL V320LA10P Littlefuse 118 2 SCREW MACHINE PHIL 4-40 X 5/16 SS PMSSS 440 0031 PH Building Fasteners 119 5 SCREW MACHINE PHIL 4-40 X 1/4 SS PMSSS 440 0025 PH Building Fasteners 120 4 1892 Keystone 121 1 RV1 SCREW1 SCREW2 SCREW3SCREW7 STDOFF1STDOFF4 T1 BQ32/30-1112CPFR TDK 122 1 T2 92 4 93 94 1 MΩ, 1%, 1/4 W, Metal Film Standoff Hex, 4-40, 0.375" L, Al, F/F Bobbin, PQ32/30, Vertical, 12 pins Bobbin, EF20, Vertical, 10 pins 123 1 U1 CAPZero, SO-8C CAP004DG Power Integrations 124 1 U2 HiperPFS-2, ESIP16/13 PFS7328H Power Integrations 125 2 U3 U6 HCPL-817-56AE Avago Technologies 126 1 U4 LCS703HG Power Integrations 127 2 U5 U8 128 1 U7 129 1 VR1 150 V, 5 W, 5%, TVS, DO204AC (DO-15) 130 1 VR2 9.1 V, 5%, 150 mW, SSMINI-2 131 1 132 3 133 3 134 3 VR3 WASHER1WASHER3 WIRE14AWG _INS_J1 WIRE14AWG _INS_J11 WIRE14AWG _INS_J12 WIRE14AWG _INS_J2 WIRE14AWG 第19页（共70页） Optocoupler, TRAN OUT 4-SMD HiperLCS, ESIP16/13 IC, REG ZENER SHUNT ADJ SOT-23 TinySwitch-III, DIP-8C LM431AIM3/NOPB National Semi TNY279PG Power Integrations P6KE150A Littlefuse DZ2S091M0L Panasonic BZX84C13LT1G On Semi FWSS 004 Building Fasteners Wire, UL1015, #14 AWG, Blk, PVC, Length To be specified by designer 1015-14/41-00 Anixter Wire, UL1015, #14 AWG, Red, PVC, Length To be specified by designer 1015-14/41-02 Anixter 13 V, 5%, 225 mW, SOT23 WASHER FLAT #4 SS Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 _INS_J9 WIRE14AWG _INS_J10 WIRE22AWG 135 1 _INS1 WIRE22AWG 136 1 _INS2 Daughter Board BOM Wire, UL1007, #22 AWG, Blk, PVC, Length To be specified by designer Wire, UL1007, #22 AWG, Red, PVC, Length To be specified by designer 22-Jan-14 1007-22/7-00 Anixter 1007-22/7-02 Anixter 1 1 C49 100 nF, 25 V, Ceramic, X7R, 0603 2 1 C50 3 1 J13 4 2 J14 J115 100 nF, 25 V, Ceramic, X7R, 1206 2 Position (1 x 2) header, 0.1 pitch, RT angle, gold 4.00 mm Header, 4 Circuits, 3.81 mm Tail Length 5 2 Q2 Q3 6 1 R56 270 kΩ, 5%, 1/10 W, Thick Film, 0603 7 1 R57 1 Ω, 5%, 1/4 W, Carbon Film CFR-25JB-1R0 Yageo 8 2 R58 R59 1.5 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ152V Panasonic 9 2 R60 R61 10 kΩ, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ103V Panasonic 10 1 U9 IC SMART DVR SYNC RECT 8-SOIC SRK2000DTR ST Micro 40 V, 85 A N-Channel, DFN5X6 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com VJ0603Y104KNXAO Vishay C1206F104K3RACTU Kemet TSW-102-08-L-S-RA Samtec Inc 75730-0204 Molex AON6232 Alpha & Omega Semi ERJ-3GEYJ274V Panasonic 第20页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 7 散热片组件 7.1 LLC散热片 7.1.1 LLC散热片工程图和装配 第21页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 7.1.2 PFS散热片工程图和装配 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第22页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 7.1.3 桥式整流管散热片工程图和装配 第23页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 8 磁芯元件 8.1 PFC扼流圈(L3)规格 8.1.1 电气原理图 Figure 12 – PFC Choke Electrical Diagram. 8.1.2 电气规格 Inductance Pins 1-FL1 measured at 100 kHz, 0.4 VRMS . 500 μH ±5% 8.1.3 材料 Item [1] [2] Description Core: PQ32/20, PC44 core material. Served litz wire: #40 / #38 AWG. 8.1.4 PFC电感总装 Figure 13 – PFC Choke Final Assembly. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第24页（共70页） 22-Jan-14 8.2 DER-385：255 W 80 PLUS白金级PC电源 LLC变压器(T1)规格 8.2.1 电气原理图 Figure 14 – LLC Transformer Electrical Diagram. 8.2.2 电气规格 Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 1 second, 60 Hz, from pins 4-6 and pins 7-12. Pins 4-6, all other windings open, measured at 100 kHz, 0.4 VRMS. Pins 4-6, all other windings open Pins 4-6, with pins 7,9,10 and 12 shorted, measured at 100 kHz, 0.4 VRMS. 3000 VAC 650 μH ±5%. 1400 kHz (Min.) 115 μH ±10%. 8.2.3 材料 Item [1] [2] [3] [4] [5] [6] [7] [8] Description 2 Core: PQ32/30-TDK PC95 and gapped ALG 560 nH/T . Bobbin: PQ32/30-Vertical, 12 pins (6/6). Magnet wire: 75 / #40 AWG Served Litz. Magnet wire: 300 / 0.1 mm Unserved Litz; or 300/#38 AWG Unserved Litz. Margin tape: 3M 44, margin tape, cream, 6.0 mm wide; or equivalent. Tape: 3M 1298 Polyester Film, 8.0 mm wide, 2.0 mils thick; or equivalent. Tape: 3M 1298 Polyester Film, 18.0 mm wide, 2.0 mils thick or equivalent. Teflon tube: #16, Alpha Wire TFT-200016. 第25页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 8.2.4 结构图 Figure 15 – LLC Transformer Build Diagram. 8.2.5 绕制说明 Winding Preparation WD1 & WD2 Secondary Insulation WD3 Primary Insulation Final Assembly Place the bobbin on the mandrel with the pin side is on the left side. Winding direction is clockwise direction. Place margin tape item [5] on the bobbin with to create 2 chambers with location shown as in fig. 2 above. Prepare 2 strands of wire item [4] ~ 8” length, tin ends. Label one strand to distinguish from other and designate it as FL1, FL2. Other strand will be designated as FL3 and FL4. Twist these 2 strands together ~8 twists evenly along length leaving 1” free at each end. Tin other ends. Use wires assembly prepared above, start with FL1 on pin 7 and FL3 on pin 9, tightly wind 2 turns in left chamber. Finish with FL2 on pin 10 and FL4 in pin 12. Secure winding with tape item [6]. Place 1 layer of tape item [5]. Start at pin 4, wind 34 turns of wire item [3] in the right chamber with tight tension and finish at pin 6. Insert Teflon tubes ~ 20 mm long item [8] for both ends of this winding. Place 2 layers of tape item [7]. Grind, assemble, and secure core halves with tape. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第26页（共70页） 22-Jan-14 8.3 DER-385：255 W 80 PLUS白金级PC电源 待机变压器(T2)规格 8.3.1 电气原理图 Figure 16 – Transformer Electrical Diagram. 8.3.2 电气规格 Electrical Strength Primary Inductance Resonant Frequency Leakage Inductance 1 second, 60 Hz, from pins 1-5 to pins 6-10. Pins 1-3, all other windings open, measured at 100 kHz, 0.4 VRMS. Pins 1-3, all other windings open. Pins 1-3, with secondary pins shorted, measured at 100 kHz, 0.4 V RMS. 3000 VAC 1157 μH ±10% 1.2 MHz (Min.) 15 μH (Max.) 8.3.3 材料 Item [1] [2] [3] [4] [5] [6] [7] Description Core: EF20. part #: PC44EF20-Z. Bobbin: EF20, Vertical, 10 pins, (5/5). Magnet wire: #29 AWG. Magnet wire: #31 AWG. Magnet wire: #25 AWG Triple Insulated Wire. Tape: 3M 1298 Polyester Film, 2 mils thick, 20 mm wide. Varnish. 第27页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 8.3.4 变压器结构图 Figure 17 – Bias Transformer Build Diagram. 8.3.5 变压器构建说明 Winding Preparation WD1 st 1 Primary Insulation WD2 Auxiliary Insulation WD3 Secondary Insulation WD4 nd 2 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 3, wind 54 turns of wire item [3] from left to right with tight tension in two layers, and terminate at pin 2 2 layers of tape item [6] Start at pin 5, wind 11 bi-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 4 2 layers of tape item [6] Start at pin 8 wind 9 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 10 2 layers of tape item [6] Start at pin 2, wind 35 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 1 3 layers of tape item [6] Assemble, grind the cores to get 1.157 mH, and secure the cores with tape. Varnish [7] Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第28页（共70页） 22-Jan-14 8.4 DER-385：255 W 80 PLUS白金级PC电源 输出电感(L4)规格 8.4.1 电气原理图 Figure 18 – Inductor Electrical Diagram. 8.4.2 电气规格 Pins FL1-FL2, all other windings open, measured at 100 kHz, 0.4 VRMS. Inductance 500 nH, ±15% 8.4.3 材料 Item [1] [2] Description Powdered Iron Toroidal Core: Micrometals T60-52. Magnet wire: #17 AWG Solderable Double Coated. 第29页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 9 LLC转换器设计表格 HiperLCS_042413; Rev.1.3; Copyright INPUTS Power Integrations 2013 Enter Input Parameters Vbulk_nom 380 OUTPUTS UNITS 380 V Vbrownout 280 V Vbrownin VOV_shut VOV_restart 353 465 448 V V V 220 uF 29.5 ms CBULK 220.00 tHOLDUP INFO Enter LLC (secondary) outputs VO1 12.00 12.0 V IO1 VD1 PO1 VO2 IO2 VD2 PO2 P_LLC LCS Device Selection Device RDS-ON (MAX) Coss Cpri Pcond_loss Tmax-hs 19.71 0.10 19.7 0.10 237 0.0 0.0 0.70 0.00 237 A V W V A V W W LCS703 1.12 312 40 2.8 90 ohms pF pF W deg C 8.7 deg C/W Theta J-HS HiperLCS_042413_Rev1-3.xls; HiperLCS HalfBridge, Continuous mode LLC Resonant Converter Design Spreadsheet Nominal LLC input voltage Brownout threshold voltage. HiperLCS will shut down if voltage drops below this value. Allowable value is between 65% and 76% of Vbulk_nom. Set to 65% for max holdup time Startup threshold on bulk capacitor OV protection on bulk voltage Restart voltage after OV protection. Minimum value of bulk cap to meet holdup time requirement; Adjust holdup time and Vbrownout to change bulk cap value Bulk capacitor hold up time The spreadsheet assumes AC stacking of the secondaries Main Output Voltage. Spreadsheet assumes that this is the regulated output Main output maximum current Forward voltage of diode in Main output Output Power from first LLC output Second Output Voltage Second output current Forward voltage of diode used in second output Output Power from second LLC output Specified LLC output power LCS Device RDS-ON (max) of selected device Equivalent Coss of selected device Stray Capacitance at transformer primary Conduction loss at nominal line and full load Maximum heatsink temperature Thermal resistance junction to heatsink (with grease and no insulator) Expected Junction 115 deg C Expectd Junction temperature temperature Ta max 50 deg C Expected max ambient temperature Theta HS-A 14 deg C/W Required thermal resistance heatsink to ambient LLC Resonant Parameter and Transformer Calculations (generates red curve) Desired Input voltage at which power train operates at Vres_target 380.00 380 V resonance. If greater than Vbulk_nom, LLC operates below resonance at VBULK. Po 238 W LLC output power including diode loss Main Output voltage (includes diode drop) for Vo 12.10 V calculating Nsec and turns ratio Desired switching frequency at Vbulk_nom. 66 kHz to f_target 90.00 90 kHz 300 kHz, recommended 180-250 kHz Parallel inductance. (Lpar = Lopen - Lres for integrated Lpar 535 uH transformer; Lpar = Lmag for non-integrated lowleakage transformer) Primary open circuit inductance for integrated Lpri 650.00 650 uH transformer; for low-leakage transformer it is sum of primary inductance and series inductor. If left blank, Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第30页（共70页） 22-Jan-14 Lres DER-385：255 W 80 PLUS白金级PC电源 115.00 Kratio Cres 115.0 uH 4.7 27.00 Lsec m n_eq 27.0 nF 2.249 uH 50 % 15.42 Npri 34.0 34.0 Nsec 2.0 2.0 auto-calculation shows value necessary for slight loss of ZVS at ~80% of Vnom Series inductance or primary leakage inductance of integrated transformer; if left blank auto-calculation is for K=4 Ratio of Lpar to Lres. Maintain value of K such that 2.1 < K < 11. Preferred Lres is such that K<7. Series resonant capacitor. Red background cells produce red graph. If Lpar, Lres, Cres, and n_RATIO_red_graph are left blank, they will be autocalculated Secondary side inductance of one phase of main output; measure and enter value, or adjust value until f_predicted matches what is measured ; Leakage distribution factor (primary to secondary). >50% signifies most of the leakage is in primary side. Gap physically under secondary yields >50%, requiring fewer primary turns. Turns ratio of LLC equivalent circuit ideal transformer Primary number of turns; if input is blank, default value is auto-calculation so that f_predicted = f_target and m=50% Secondary number of turns (each phase of Main output). Default value is estimate to maintain BAC<=200 mT, using selected core (below) Expected frequency at nominal input voltage and full load; Heavily influenced by n_eq and primary turns Series resonant frequency (defined by series inductance Lres and C) Expected switching frequency at Vbrownout, full load. Set HiperLCS minimum frequency to this value. Parallel resonant frequency (defined by Lpar + Lres and C) LLC full load gain inversion frequency. Operation below this frequency results in operation in gain inversion region. LLC full load gain inversion point input voltage Expected value of input voltage at which LLC operates at resonance. f_predicted 92 kHz f_res 90 kHz f_brownout 62 kHz f_par 38 kHz f_inversion 56 kHz Vinversion 252 V Vres_expected 373 V 1.59 A Primary winding RMS current at full load, Vbulk_nom and f_predicted 15.6 A Winding 1 (Lower secondary Voltage) RMS current 9.8 A Lower Secondary Voltage Capacitor RMS current 0.0 A Winding 2 (Higher secondary Voltage) RMS current 0.0 A Higher Secondary Voltage Capacitor RMS current 102 V Resonant capacitor AC RMS Voltage at full load and nominal input voltage RMS Currents and Voltages IRMS_LLC_Primary Winding 1 (Lower secondary Voltage) RMS current Lower Secondary Voltage Capacitor RMS current Winding 2 (Higher secondary Voltage) RMS current Higher Secondary Voltage Capacitor RMS current Cres_Vrms Virtual Transformer Trial - (generates blue curve) New primary turns 34.0 New secondary turns 2.0 New Lpri 650 uH New Cres 27.0 nF 第31页（共70页） Trial transformer primary turns; default value is from resonant section Trial transformer secondary turns; default value is from resonant section Trial transformer open circuit inductance; default value is from resonant section Trial value of series capacitor (if left blank calculated value chosen so f_res same as in main resonant Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 section above New estimated Lres New estimated Lpar New estimated Lsec New Kratio New equivalent circuit transformer turns ratio V powertrain inversion new f_res_trial f_predicted_trial 115.0 535 2.249 4.7 IRMS_LLC_Primary Winding 1 (Lower secondary Voltage) RMS current Lower Secondary Voltage Capacitor RMS current Winding 2 (Higher secondary Voltage) RMS current Higher Secondary Voltage Capacitor RMS current uH uH uH 15.42 Trial transformer estimated Lres Estimated value of Lpar for trial transformer Estimated value of secondary leakage inductance Ratio of Lpar to Lres for trial transformer Estimated effective transformer turns ratio 252 V Input voltage at LLC full load gain inversion point 90 92 kHz kHz 1.59 A 15.7 A RMS current through Output 1 winding, assuming half sinusoidal waveshape 10.2 A Lower Secondary Voltage Capacitor RMS current 15.7 A RMS current through Output 2 winding; Output 1 winding is AC stacked on top of Output 2 winding 0.0 A Higher Secondary Voltage Capacitor RMS current New Series resonant frequency New nominal operating frequency Primary winding RMS current at full load and nominal input voltage (Vbulk) and f_predicted_trial Expected value of input voltage at which LLC operates at resonance. Transformer Core Calculations (Calculates From Resonant Parameter Section) Transformer Core PQ32/30 PQ32/30 Transformer Core Ae 1.61 cm^2 Enter transformer core cross-sectional area Ve 12.00 cm^3 Enter the volume of core Aw 95.3 mm^2 Area of window Bw 18.6 mm Total Width of Bobbin Enter the loss per unit volume at the switching Loss density 200.0 mW/cm^3 frequency and BAC (Units same as kW/m^3) MLT 6.7 cm Mean length per turn Nchambers 2 Number of Bobbin chambers Winding separator distance (will result in loss of winding Wsep 6.00 6.0 mm area) Ploss 2.4 W Estimated core loss Bpkfmin 152 mT First Quadrant peak flux density at minimum frequency. AC peak to peak flux density (calculated at f_predicted, BAC 205 mT Vbulk at full load) Primary Winding Number of primary turns; determined in LLC resonant Npri 34.0 section Primary gauge 40 40 AWG Individual wire strand gauge used for primary winding Equivalent Primary 0.080 mm Equivalent diameter of wire in metric units Metric Wire gauge Number of strands in Litz wire; for non-litz primary Primary litz strands 75 75 winding, set to 1 Primary Winding Primary window allocation factor - percentage of 50 % Allocation Factor winding space allocated to primary AW_P 32 mm^2 Winding window area for primary Fill Factor 66% % % Fill factor for primary winding (typical max fill is 60%) Resistivity_25 49.72 m-ohm/m Resistivity in milli-ohms per meter C_Primary Primary DCR 25 C 113.43 m-ohm Estimated resistance at 25 C Estimated resistance at 100 C (approximately 33% Primary DCR 100 C 152.00 m-ohm higher than at 25 C) Vres_expected_trial 373 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com V 第32页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 Primary RMS current ACR_Trf_Primary Primary copper loss Primary Layers 1.59 A 329.24 m-ohm 0.84 4.84 W Secondary Winding 1 (Lower secondary voltage OR Single output) Output Voltage Sec 1 Turns Sec 1 RMS current (total, AC+DC) Winding current (DC component) Winding current (AC RMS component) Measured RMS current through the primary winding Measured AC resistance (at 100 kHz, room temperature), multiply by 1.33 to approximate 100 C winding temperature Total primary winding copper loss at 85 C Number of layers in primary Winding Note - Power loss calculations are for each winding half of secondary Output Voltage (assumes AC stacked windings) Secondary winding turns (each phase ) RMS current through Output 1 winding, assuming half sinusoidal waveshape 12.00 2.00 V 15.6 A 9.86 A DC component of winding current 12.10 A AC component of winding current Sec 1 Wire gauge 38 AWG Equivalent secondary 1 Metric Wire gauge 0.100 mm Sec 1 litz strands 300 Resistivity_25 C_sec1 DCR_25C_Sec1 Individual wire strand gauge used for secondary winding Equivalent diameter of wire in metric units Number of strands used in Litz wire; for non-litz nonintegrated transformer set to 1 300 7.82 m-ohm/m 1.05 m-ohm DCR_100C_Sec1 1.41 m-ohm DCR_Ploss_Sec1 1.09 W ACR_Sec1 1.41 m-ohm ACR_Ploss_Sec1 Total winding 1 Copper Losses Capacitor RMS current Co1 Capacitor ripple voltage 0.41 W 1.51 W 9.8 A Output capacitor RMS current 540.0 uF 0.5 % 15.6 A Secondary 1 output capacitor Peak to Peak ripple voltage on secondary 1 output capacitor Schottky losses are a stronger function of load DC current. Sync Rectifier losses are a function of RMS current Number of layers in secondary 1 Winding Note - Power loss calculations are for each winding half of secondary Output Voltage (assumes AC stacked windings) Secondary winding turns (each phase) AC stacked on top of secondary winding 1 RMS current through Output 2 winding; Output 1 winding is AC stacked on top of Output 2 winding 540.00 Output rectifier RMS Current Secondary 1 Layers 2.00 2.00 Secondary Winding 2 (Higher secondary voltage) Output Voltage 0.00 Sec 2 Turns 0.00 Sec 2 RMS current (total, AC+DC) Winding current (DC component) Winding current (AC RMS component) V Resistivity in milli-ohms per meter Estimated resistance per phase at 25 C (for reference) Estimated resistance per phase at 100 C (approximately 33% higher than at 25 C) Estimated Power loss due to DC resistance (both secondary phases) Measured AC resistance per phase (at 100 kHz, room temperature), multiply by 1.33 to approximate 100 C winding temperature. Default value of ACR is twice the DCR value at 100 C Estimated AC copper loss (both secondary phases) Total (AC + DC) winding copper loss for both secondary phases 15.6 A 0.0 A DC component of winding current 0.0 A AC component of winding current Sec 2 Wire gauge 38 AWG Equivalent secondary 2 Metric Wire gauge 0.100 mm Sec 2 litz strands 第33页（共70页） 0 Individual wire strand gauge used for secondary winding Equivalent diameter of wire in metric units Number of strands used in Litz wire; for non-litz nonintegrated transformer set to 1 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 Resistivity_25 C_sec2 Transformer Secondary MLT DCR_25C_Sec2 22-Jan-14 23453.09 m-ohm/m 6.71 cm 0.00 m-ohm DCR_100C_Sec2 0.00 m-ohm DCR_Ploss_Sec1 0.00 W ACR_Sec2 0.00 m-ohm ACR_Ploss_Sec2 Total winding 2 Copper Losses Capacitor RMS current Co2 Capacitor ripple voltage 0.00 W 0.00 W 0.0 A Output capacitor RMS current N/A uF N/A % 0.0 A Secondary 2 output capacitor Peak to Peak ripple voltage on secondary 1 output capacitor Schottky losses are a stronger function of load DC current. Sync Rectifier losses are a function of RMS current Number of layers in secondary 2 Winding Does not include fringing flux loss from gap 0.84 W Total primary winding copper loss at 85 C 1.51 W Total copper loss in secondary winding Output rectifier RMS Current 1.00 Resistivity in milli-ohms per meter Mean length per turn Estimated resistance per phase at 25 C (for reference) Estimated resistance per phase at 100 C (approximately 33% higher than at 25 C) Estimated Power loss due to DC resistance (both secondary halves) Measured AC resistance per phase (at 100 kHz, room temperature), multiply by 1.33 to approximate 100 C winding temperature. Default value of ACR is twice the DCR value at 100 C Estimated AC copper loss (both secondary halves) Total (AC + DC) winding copper loss for both secondary halves Secondary 2 Layers Transformer Loss Calculations Primary copper loss (from Primary section) Secondary copper Loss Transformer total copper loss AW_S 2.34 W Total copper loss in transformer (primary + secondary) 32.28 mm^2 Secondary Fill Factor 49% % Area of window for secondary winding % Fill factor for secondary windings; typical max fill is 60% for served and 75% for unserved Litz 62 kHz ns Signal Pins Resistor Values f_min Dead Time 625 625 Burst Mode 2 2 Minimum frequency when optocoupler is cut-off. Only change this variable based on actual bench measurements Dead time Select Burst Mode: 1, 2, and 3 have hysteresis and have different frequency thresholds Max internal clock frequency, dependent on dead-time setting. Is also start-up frequency Lower threshold frequency of burst mode, provides hysteresis. This is switching frequency at restart after a bursting off-period Upper threshold frequency of burst mode; This is switching frequency at which a bursting off-period stops f_max 434 kHz f_burst_start 160 kHz f_burst_stop 187 kHz 14.93 k-ohms Resistor from DT/BF pin to VREF pin 134 k-ohms Resistor from DT/BF pin to G pin DT/BF pin upper divider resistor DT/BF pin lower divider resistor Rstart Start up delay Rfmin 5.76 5.76 k-ohms 1.0 ms 133.3 k-ohms Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com Start-up resistor - resistor in series with soft-start capacitor; equivalent resistance from FB to VREF pins at startup. Use default value unless additional start-up delay is desired. Start-up delay; delay before switching begins. Reduce R_START to increase delay Resistor from VREF pin to FB pin, to set min operating frequency; This resistor plus Rstart determine f_MIN. Includes 7% HiperLCS frequency tolerance to ensure f_min is below f_brownout 第34页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 C_softstart Ropto OV/UV pin lower 20.00 resistor OV/UV pin upper resistor LLC Capacitive Divider Current Sense Circuit Slow current limit 3.62 Fast current limit LLC sense capacitor RLLC sense resistor IS pin current limit resistor IS pin noise filter capacitor IS pin noise filter pole frequency Loss Budget LCS device Conduction loss Output diode Loss Transformer estimated total copper loss Transformer estimated total core loss Total transformer losses Total estimated losses Estimated Efficiency PIN 100 2.4 k-ohms Softstart capacitor. Recommended values are between 0.1 uF and 0.47 uF Resistor in series with opto emitter 20.0 k-ohm Lower resistor in OV/UV pin divider 2.92 M-ohm Total upper resistance in OV/UV pin divider 3.62 A 6.52 A 100 pF 37.4 ohms 220 ohms 1.0 nF 724 kHz 2.8 W Conduction loss at nominal line and full load 2.0 W Estimated diode losses 2.34 W Total copper loss in transformer (primary + secondary) 2.4 W Estimated core loss 4.7 W Total transformer losses 9.6 W Total losses in LLC stage 96% 246 % W Estimated efficiency LLC input power This is to help you choose the secondary turns Outputs not connected to any other part of spreadsheet Target regulated output voltage Vo1. Change to see effect on slave output Diode drop voltage for Vo1 Total number of turns for Vo1 Expected output Target output voltage Vo2 Diode drop voltage for Vo2 Total number of turns for Vo2 Expected output voltage Not applicable if using integrated magnetics - not connected to any other part of spreadsheet Desired inductance of separate inductor Inductor core cross-sectional area Number of primary turns AC flux for core loss calculations (at f_predicted and full load) 0.33 uF This pole attenuates IS pin signal Secondary Turns and Voltage Centering Calculator V1 12.00 V V1d1 N1 V1_Actaul V2 V2d2 N2 V2_Actual 0.10 3.00 12.00 0.00 0.70 1.00 3.33 V V V V V Separate Series Inductor (For Non-Integrated Transformer Only) Lsep Ae_Ind Inductor turns 115.00 0.53 27 uH cm^2 BP_fnom 194 mT Expected peak primary current 3.6 A BP_fmin 294 mT Inductor Litz gauge 40 AWG 第35页（共70页） 8-cycle current limit - check positive half-cycles during brownout and startup 1-cycle current limit - check positive half-cycles during startup HV sense capacitor, forms current divider with main resonant capacitor LLC current sense resistor, senses current in sense capacitor Limits current from sense resistor into IS pin when voltage on sense R is < -0.5V IS pin bypass capacitor; forms a pole with IS pin current limit capacitor Expected peak primary current Peak flux density, calculated at minimum frequency fmin Individual wire strand gauge used for primary winding Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 Equivalent Inductor Metric Wire gauge Inductor litz strands Inductor parallel wires Resistivity_25 C_Sep_Ind Inductor MLT Inductor DCR 25 C 22-Jan-14 0.080 mm 125.00 Number of strands used in Litz wire 1 Number of parallel individual wires to make up Litz wire 29.8 m-ohm/m 7.00 56.4 cm m-ohm Inductor DCR 100 C 75.6 m-ohm ACR_Sep_Inductor 120.9 m-ohm Inductor copper loss Feedback section VMAIN ITL431_BIAS 0.31 W 12.0 1.0 mA VF 1.0 V VCE_SAT 0.3 V CTR_MIN 0.8 VTL431_SAT 2.5 V RLED_SHUNT 1.0 k-ohms 2.40 k-ohms 177.70 uA IOPTO_BJT_MAX 1.42 mA RLED_SERIES_MA X 2.76 k-ohms ROPTO_LOAD IFMAX Auto 2.40 Equivalent diameter of wire in metric units Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com Resistivity in milli-ohms per meter Mean length per turn Estimated resistance at 25 C (for reference) Estimated resistance at 100 C (approximately 33% higher than at 25 C) Measured AC resistance (at 100 kHz, room temperature), multiply by 1.33 to approximate 100 C winding temperature Total primary winding copper loss at 85 C Output voltage rail that optocoupler LED is connected to Minimum operating current in TL431 cathode Typical Optocoupler LED forward voltage at IOPTO_BJTMAX (max current) Optocoupler transistor saturation voltage Optocoupler minimum CTR at VCE_SAT and at IOPTO_BJT_MAX TL431 minimum cathode voltage when saturated Resistor across optocoupler LED to ensure minimum TL431 bias current is met Resistor from optocoupler emitter to ground, sets load current FB pin current when switching at FMAX (e.g. startup) Optocoupler transistor maximum current - when bursting at FMAX (e.g. startup) Maximum value of gain setting resistor, in series with optocoupler LED, to ensure optocoupler can deliver IOPTO_BJT_MAX. Includes -10% tolerance factor. 第36页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 10 待机转换器设计表格 ACDC_TinySwitchIII_042413; Rev.1.27; INPUT Copyright Power Integrations 2008 ENTER APPLICATION VARIABLES VACMIN 85 VACMAX 265 fL 50 VO 11.50 IO INFO 1.57 n 0.70 Z 0.50 tC 3.00 CIN 220.00 ENTER TinySwitch-III VARIABLES TinySwitch-III TNY279G Chosen Device STD UNIT Volts Volts Hertz Volts Amps Power Chose Configuration OUTPUT 18.055 Watts 220 mSeconds uFarads 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 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 Input Capacitance User defined TinySwitch-III TNY279G TNY279G Standard Current Limit ILIMITMIN ILIMITTYP ILIMITMAX fSmin 0.605 0.650 0.709 124000 Amps Amps Amps Hertz I^2fmin 50.193 A^2kHz VOR 120 Volts VDS VD KP 10 0.7 0.60 Volts Volts KP_TRANSIENT 0.34 ENTER BIAS WINDING VARIABLES VB 14 VDB NB VZOV UVLO VARIABLES 14.00 0.70 10.33 20.00 Volts Volts V_UV_TARGET 124.49 Volts V_UV_ACTUAL 119.70 Volts RUV_IDEAL 4.89 Mohms RUV_ACTUAL 4.70 Mohms ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EF20 EF20 Core EF20 Bobbin EF20_BOB 第37页（共70页） ACDC_TinySwitch-III_042413_Rev1-27.xls; TinySwitch-III Continuous/Discontinuous Flyback Transformer Design Spreadsheet Volts P/N: P/N: Enter "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 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) TinySwitch-III 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 Bias Winding Voltage Bias Winding Diode Forward Voltage Drop Bias Winding Number of Turns Over Voltage Protection zener diode voltage. Target DC under-voltage threshold, above which the power supply with start Typical DC start-up voltage based on standard value of RUV_ACTUAL Calculated value for UV Lockout resistor Closest standard value of resistor to RUV_IDEAL Enter Transformer Core PC40EF20-Z EF20_BOBBIN Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 BIN AE LE AL BW 0.335 4.49 1570 12.2 cm^2 cm nH/T^2 mm M 0 mm L NS DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS 3 9 113 375 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 Volts Volts 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 DMAX 0.54 IAVG IP IR IRMS TRANSFORMER PRIMARY DESIGN PARAMETERS 0.25 0.61 0.36 0.38 Amps Amps Amps Amps LP 1157 uHenries LP_TOLERANCE NP ALG 10 89 148 % nH/T^2 BM 2766 Gauss BAC 828 Gauss ur LG BWE 1675 0.26 36.6 mm mm OD 0.41 mm INS 0.06 mm DIA 0.35 mm AWG 28 AWG CM 161 Cmils CMA 430 Cmils/Amp TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP 5.95 ISRMS 3.42 IRIPPLE 3.04 Amps Amps Amps CMS 684 Cmils AWGS 21 AWG VDRAIN 647 Volts PIVS 50 Volts Typical Primary Inductance. +/- 10% to ensure a minimum primary inductance of 1041 uH 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 Primary Winding Current Capacity (200 < CMA < 500) 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 Maximum Drain Voltage Estimate (Assumes 20% zener clamp tolerance and an additional 10% temperature tolerance) Output Rectifier Maximum Peak Inverse Voltage TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第38页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 VO1 11.5 Volts IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 1.570 18.06 0.7 9.00 3.422 3.04 Amps Watts Volts 50 Volts PIVS1 Recommended Diodes Amps Amps SB560 CMS1 684 Cmils AWGS1 21 AWG DIAS1 0.73 mm ODS1 1.36 mm 2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 0.00 0.7 0.52 0.000 0.00 PIVS2 Volts Amps Watts Volts Amps Amps 2 Volts 0 Cmils AWGS2 N/A AWG DIAS2 N/A mm ODS2 N/A mm Recommended Diode CMS2 3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 0.00 0.7 0.52 0.000 0.00 PIVS3 Volts Amps Watts Volts Amps Amps 2 Volts 0 Cmils AWGS3 N/A AWG DIAS3 N/A mm ODS3 N/A mm 18.055 Watts Recommended Diode CMS3 Total power Negative Output 第39页（共70页） N/A N/A Main Output Voltage (if unused, defaults to single output design) Output DC Current 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 Recommended Diodes for this output 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 Output Voltage Output DC Current 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 Recommended Diodes for this output 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 Output Voltage Output DC Current 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 Recommended Diodes for this output 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 Total Output Power If negative output exists enter Output number; eg: If VO2 is negative output, enter 2 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 11 功率因数控制器设计表格 Hiper_PFS-II_Boost_101813; Rev.1.2; Copyright Power Integrations 2013 INPUT INFO Enter Applications Variables Input Voltage Range VACMIN VACMAX VBROWNIN VBROWNOUT VO PO fL TA Max 385.00 265.00 OUTPUT UNITS Universal 90 265 V V 76.69 V 68.33 385.00 265.00 50 40 V V W Hz deg C 0.93 n KP VO_MIN VO_RIPPLE_MAX tHOLDUP 0.450 0.45 18.00 365.75 20 18 V V ms VHOLDUP_MIN 310 V I_INRUSH 40 A Forced Air Cooling Yes Yes PFS Parameters PFS Part Number Auto PFS7328H EFFICIENCY EFFICIENCY MODE R_RPIN C_RPIN IOCP min IOCP typ IOCP max RDSON RV1 RV2 RV3 C_VCC R_VCC C_V 49.9 1.00 9.00 9.50 9.90 0.46 1.50 1.50 1.00 3.30 15.00 22.00 k-ohms nF A A A ohms Mohms Mohms Mohms uF ohms nF C_C 22.00 nF Power_Good_Vo_Threshold_VPG(L) 333.00 V PGT set resistor 103.79 kohm FS_PK 65.4 kHz FS_AVG 53.0 kHz Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com Hiper_PFSII_Boost_100413_Rev1-2.xls; Continuous Mode Boost Converter Design Spreadsheet Input voltage range Minimum AC input voltage Maximum AC input voltage Expected Minimum Brown-in Voltage Specify brownout voltage. Nominal Output voltage Nominal Output power Line frequency Maximum ambient temperature Enter the efficiency estimate for the boost converter at VACMIN Ripple to peak inductor current ratio at the peak of VACMIN Minimum Output voltage Maximum Output voltage ripple Holdup time Minimum Voltage Output can drop to during holdup Maximum allowable inrush current Enter "Yes" for Forced air cooling. Otherwise enter "No" Selected PFS device Mode of operation of PFS. For full mode enter "FULL" otherwise enter "EFFICIENCY" to indicate efficiency mode R pin resistor value R pin capacitor value Minimum Current limit Typical current limit Maximum current limit Typical RDSon at 100 'C Line sense resistor 1 Line sense resistor 2 Line sense resistor 3 Supply decoupling capacitor VCC resistor V pin decoupling capacitor Feedback C pin decoupling capacitor Vo threshold at which VPG is triggered Power good threshold setting resistor Estimated frequency of operation at crest of input voltage (at VACMIN) Estimated average frequency of operation over line cycle (at 第40页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 VACMIN) IP PFS_IRMS PCOND_LOSS_PFS PSW_LOSS_PFS PFS_TOTAL 5.25 2.59 3.08 1.30 4.39 A A W W W TJ Max 100 deg C Rth-JS 3.00 degC/W HEATSINK Theta-CA 6.52 degC/W LPFC 501 uH LPFC (0 Bias) 501 uH 5 % 3.07 A MOSFET peak current PFS MOSFET RMS current Estimated PFS conduction losses Estimated PFS switching losses Total Estimated PFS losses Maximum steady-state junction temperature Maximum thermal resistance (Junction to heatsink) Maximum thermal resistance of heatsink Basic Inductor Calculation LP_TOL 5.00 LPFC_RMS Value of PFC inductor at peak of VACMIN and Full Load Value of PFC inductor at No load. This is the value measured with LCR meter Tolerance of PFC Inductor Value Inductor RMS current (calculated at VACMIN and Full Load) Inductor Construction Parameters Core Type Ferrite Ferrite Core Material Auto PC44 Core Geometry Auto PQ PQ32/20 PQ32/20 170 55.5 6530 9.44 5.12 67.1 8.98 56 1.64 3.07 Core AE LE AL VE HT MLT BW NL LG ILRMS Wire type LITZ LITZ AWG 38 38 Filar 40 40 OD 0.102 AC Resistance Ratio 1.02 J mm^2 mm nH/t^2 cm^3 mm cm mm mm A AWG mm 9.48 A/mm^2 3900 Gauss BM 2765 Gauss BP 3871 Gauss BP_TARGET 第41页（共70页） Warning 3900 Enter "Sendust", "Pow Iron" or "Ferrite" Select from 60u, 75u, 90u or 125 u for Sendust cores. Fixed at PC44 or equivalent for Ferrite cores. Fixed at 52 material for Pow Iron cores. Select from Toroid or EE for Sendust cores and from EE, or PQ for Ferrite cores Core part number Core cross sectional area Core mean path length Core AL value Core volume Core height/Height of window Mean length per turn Bobbin width Inductor turns Gap length (Ferrite cores only) Inductor RMS current Select between "Litz" or "Regular" for double coated magnet wire Inductor wire gauge Inductor wire number of parallel strands Outer diameter of single strand of wire Ratio of AC resistance to the DC resistance (using Dowell curves) !!! Warning Current density is too high and may cause heating in the inductor wire. Reduce J Target flux density at selected saturation current level (Ferrite cores only) Maximum operating flux density Peak Flux density (Estimated at selected saturation current level) Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 LPFC_CORE_LOSS LPFC_COPPER_LOSS LPFC_TOTAL LOSS FIT Warning Layers 22-Jan-14 0.09 3.23 3.33 W W W 102.63% % 5.7 Inductor saturation current Critical Parameters IRMS IO_AVG Output Diode (DO) Part Number 7.000 Info Auto Type 7.0 A 3.17 0.69 A A INTERNAL SPECIAL Manufacturer VRRM IF TRR VF PI 600 3 31 1.47 V A ns V PCOND_DIODE 1.01 W PSW_DIODE P_DIODE 0.90 1.92 W W TJ Max 100 deg C Rth-JS 3.85 degC/W HEATSINK Theta-CA 6.52 degC/W 220.00 uF VO_RIPPLE_EXPECTED 10.7 V T_HOLDUP_EXPECTED 21.6 ms ESR_LF ESR_HF 0.75 0.30 ohms ohms IC_RMS_LF 0.49 A IC_RMS_HF 1.40 A CO_LF_LOSS 0.18 W CO_HF_LOSS 0.59 W Total CO LOSS 0.77 W Input Bridge (BR1) and Fuse (F1) I^2t Rating Fuse Current rating 15.45 4.96 A^2s A Estimated Inductor core Loss Estimated Inductor copper losses Total estimated Inductor Losses !!! Warning. Windings may not fit on this inductor. Use bigger core or reduce KP or reduce wire gauge if possible Estimated layers in winding Inductor saturation current is lower than IOCP_max. Verify transient conditions on the bench. AC input RMS current Output average current PFC Diode Part Number Diode Type - Special - Diodes specially catered for PFC applications, SiC - Silicon Carbide type, UF - Ultrafast recovery type Diode Manufacturer Diode rated reverse voltage Diode rated forward current Diode Reverse recovery time Diode rated forward voltage drop Estimated Diode conduction losses Estimated Diode switching losses Total estimated Diode losses Maximum steady-state operating temperature Maximum thermal resistance (Junction to heatsink) Maximum thermal resistance of heatsink Output Capacitor CO Auto VF 0.90 V IAVG PIV_INPUT BRIDGE 3.09 375 A V Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com Minimum value of Output capacitance Expected ripple voltage on Output with selected Output capacitor Expected holdup time with selected Output capacitor Low Frequency Capacitor ESR High Frequency Capacitor ESR Low Frequency Capacitor RMS current High Frequency Capacitor RMS current Estimated Low Frequency ESR loss in Output capacitor Estimated High frequency ESR loss in Output capacitor Total estimated losses in Output Capacitor Minimum I^2t rating for fuse Minimum Current rating of fuse Input bridge Diode forward Diode drop Input average current at 70 VAC. Peak inverse voltage of input 第42页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 PCOND_LOSS_BRIDGE 5.13 W CIN 0.82 uF 9.37 1N5407 ohms R1 1.50 Mohms R3 1.60 Mohms R2 787.00 kohms C1 47.00 nF R4 60.40 kohms R6 487.00 kohms R7 7.68 kohms C2 47.00 nF R5 3.00 kohms C3 2.20 uF D1 BAV116 RT D_Precharge Feedback Components Loss Budget (Estimated at VACMIN) PFS Losses 4.39 W Boost diode Losses 1.92 W Input Bridge losses 5.13 W Inductor losses 3.33 W Output Capacitor Loss 0.77 W Total losses 15.53 W Efficiency 0.94 bridge Estimated Bridge Diode conduction loss Input capacitor. Use metallized polypropylene or film foil type with high ripple current rating Input Thermistor value Recommended precharge Diode Feedback network, first high voltage divider resistor Feedback network, third high voltage divider resistor Feedback network, second high voltage divider resistor Feedback network, loop speedup capacitor Feedback network, lower divider resistor Feedback network - pole setting resistor Feedback network - zero setting resistor Feedback component- noise suppression capacitor Damping resistor in serise with C3 Feedback network - compensation capacitor Feedback network - capacitor failure detection Diode Total estimated losses in PFS Total estimated losses in Output Diode Total estimated losses in input bridge module Total estimated losses in PFC choke Total estimated losses in Output capacitor Overall loss estimate Estimated efficiency at VACMIN. Verify efficiency at other line voltages CAPZero component selection recommendation CAPZero Device CAP002DG Total Series Resistance (R1+R2) 1.50 k-ohms (Optional) Recommended CAPZero device to discharge XCapacitor with time constant of 1 second Maximum Total Series resistor value to discharge X-Capacitors EMI filter components recommendation CIN 680.00 680.00 nF CX2 150.00 150.00 nF 305.49 uH 220.00 nF 10.00 mH LDM_calc CX1 LCM 第43页（共70页） 220.00 Metallized polyester film capacitor after bridge, ratio with Po X capacitor after differencial mode choke and before bridge, ratio with Po estimated minimum differencial inductance to avoid <10kHz resonance in input current X capacitor before common mode choke, ratio with Po typical common mode choke value Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 estimated leakage inductance of CM choke, typical from 30~60uH Typical Y capacitance for common CY1 (and CY2) 220.00 pF mode noise suppression cal_LDM minus LCM_leakage, LDM_Actual 245.49 uH utilizing CM leakage inductance as DM choke. Note: CX2 can be placed between CM chock and DM choke depending on EMI design requirement. LCM_leakage 60.00 60.00 uH Note: There is a warning in the spreadsheet for current density in PFC choke. Whenever such a warning is issued, thermal performance of the PFC choke should be checked while operating continuously at the lowest input voltage. In this design, it was found that the temperature rise of the choke was within acceptable limits with the available airflow. There is a warning in the spreadsheet for FIT factor, however when wounding the choke it was found that the winding can be accommodated without any problems. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第44页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 12 性能数据 All measurements were taken at room temperature and 50/60 Hz input frequency unless otherwise specified, Output voltage measurements were taken at the output connectors. 12.1 系统效率 Figures below show the total supply efficiency (PFC and LLC stages). AC input was supplied using a sine wave source. 98 100 VAC 115 VAC 230 VAC 96 Efficiency (%) 94 92 90 88 86 84 0 10 20 30 40 50 60 70 80 90 100 110 Load (%) Figure 19 – System Efficiency vs. Load. Note: Fan was running with full power and it was turned off for loads ≤50%. Note: All the efficiency readings were taken by keeping the power supply inside a metal enclosure. Note: Cable drop was not included in the efficiency measurements. Power Supply is meeting 80 plus platinum efficiency requirements. VIN (VAC) 100 / 115 / 230 100 / 115 / 230 100 / 115 / 230 第45页（共70页） Load (%) 20 50 100 Measured Efficiency (%) 91.81 / 92.17 / 91.96 93.14 / 93.41 / 94.65 90.31 / 91.17 / 93.33 Platinum Efficiency Specification (%) 90 / 90 / 90 92 / 92 / 94 89 / 89 / 91 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 12.2 功率因数 Power factor measurements were made using a sine wave AC source. 1.01 100 VAC 115 VAC 230 VAC 0.99 Power Factor 0.97 0.95 0.93 0.91 0.89 0.87 0.85 0 10 20 30 40 50 60 70 80 90 100 110 Load (%) Figure 20 – Power Factor vs. Input Voltage, 50% and 100% Load. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第46页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 12.3 THD THD measurements were taken a 100%, 50% and 20% load using a sine wave source and a Yokogawa WT310 power analyzer with harmonic measurement option. 20 100 VAC 115 VAC 230 VAC 18 16 THD (%) 14 12 10 8 6 4 2 0 10 20 30 40 50 60 70 80 90 100 Load (%) Figure 21 – THD vs. Load. 第47页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 110 DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 12.4 输出调整 The PFC regulates the LLC and standby supply input voltage under normal conditions so the outputs will not be affected by the AC input voltage. Variations due to temperature and component tolerances are not represented. The 12 V (+12 VA and +12 VB voltages after current sensing resistors) output varies by less than 1% over a line voltage range of 100 VAC to 230 VAC. 12.4.1 线电压调整 16 +12 VA +12 VB 15 Output Voltage (V) 14 13 12 11 10 9 8 0 10 20 30 40 50 60 70 80 90 100 110 Load (%) Figure 22 – Output Voltage vs. Input Line Voltage (Line Regulation). Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第48页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 12.4.2 负载调整 The 12 V output varies by less than 1% over a load range of 10% to 100% load. 16 +12VA +12VB 15 Output Voltage (V) 14 13 12 11 10 9 8 80 100 120 140 160 180 200 220 Input Voltage (VAC) Figure 23 – Output Voltage vs. Output Load Current (Load Regulation). 第49页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 240 DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 13 输入电流谐波限值与EN 61000-3-2 Class D限值 Figure 24 – AC Input Harmonics vs. EN 61000-3-2 Class D Limits, 115 VAC, 60 Hz, 100% Load. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第50页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 Figure 25 – AC Input Harmonics vs. EN 61000-3-2 Class D Limits, 230 VAC, 50 Hz, 100% Load. 第51页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 14 波形 14.1 输入电压及电流 Figure 26 – 115 VAC, 255 W Load. Upper: IIN, 2 A / div. Lower: VIN, 100 V, 5 ms / div. Figure 27 – 230 VAC, 255 W Load. Upper: IIN, 1 A / div. Lower: VIN, 200 V, 5 ms / div. 14.2 LLC初级电压及电流 The LLC stage current was measured by adding a current sensing loop between C34 and B- that measures the LLC transformer (T1) primary current. The primary voltage waveform was measured at HB node. Figure 28 – LLC Stage Primary Voltage and Current. Upper: Current, 2 A / div. Lower: Voltage, 200 V, 5 μs / div. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第52页（共70页） 22-Jan-14 14.3 DER-385：255 W 80 PLUS白金级PC电源 PFC开关电压和电流 - 正常工作 Figure 29 – PFC Stage Drain Voltage and Inductor Current, Full Load, 115 VAC Upper: IINDUCTOR, 2 A / div. Lower: VDRAIN, 200 V, 2 ms / div. Figure 30 – PFC Stage Drain Voltage and Inductor Current, Full Load, 115 VAC. Upper: IINDUCTOR, 2 A / div. Lower: VDRAIN, 200 V, 10 μs / div. (Zoom in on top of sine wave.) Figure 31 – PFC Stage Drain Voltage and Inductor Current, Full Load, 230 VAC. Upper: IINDUCTOR, 1 A / div. Lower: VDRAIN, 200 V, 2 ms / div. Figure 32 – PFC Stage Drain Voltage and Inductor Current, Full Load, 230 VAC. Upper: IINDUCTOR, 1 A / div. Lower: VDRAIN, 200 V, 10 μs / div. (Zoom in on top of sine wave.) 第53页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 14.4 启动时的AC输入电流和PFC输出电压 Figure 33 – AC Input Current vs. PFC Output Voltage at Start-up, Full Load, 115 VAC. Upper: AC IIN, 5 A / div. Lower: PFC VOUT, 200 V, 50 ms / div 14.5 22-Jan-14 Figure 34 – AC Input Current vs. PFC Output Voltage at Start-up, Full Load, 230 VAC. Upper: AC IIN, 2 A / div. Lower: PFC VOUT, 200 V, 50 ms / div. LLC启动（CR模式） Figure 35 – LLC Start-up. 115 VAC, 100% Load. Upper: LLC Primary Current, 2 A / div. Lower: LLC VOUT, 5 V, 10 ms / div. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com Figure 36 – LLC Start-up. 115 VAC, 0% Load. Upper: LLC Primary Current, 2 A / div. Lower: LLC VOUT, 5 V, 10 ms / div. 第54页（共70页） 22-Jan-14 14.6 DER-385：255 W 80 PLUS白金级PC电源 LLC电压跌落 Figure 37 – LLC Brown-out. Upper: Primary Current, 2 A / div. Lower: Main VOUT, 5 V / div. 第55页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 14.7 LLC输出短路 The figure below shows the effect of an output short circuit on the LLC primary current. A mercury displacement relay was used to short the output to get a fast, bounce-free connection. Figure 38 – Output Short Circuit Test. Upper: LLC Primary Current, 2 A / div. Lower: Main VOUT, 5 V, 100 μs / div. 14.8 主启动和待机启动（CR模式） Figure 39 – LLC Start-up. 115 VAC, 100% Load. Upper: LLC VOUT, 2 V /div, Lower: LLC IOUT, 5 A / div. 10 ms / div. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com Figure 40 – LLC Start-up. 115 VAC, 0% Load. Upper: Standby VOUT, 2 V / div. Lower: Standby IOUT, 0.5 A / div, 10 ms / div. 第56页（共70页） 22-Jan-14 Figure 41 – LLC Start-up. 115 VAC, 100% Load. Upper: LLC VOUT, 2 V / div. Lower: Standby VOUT, 2 V, 20 ms / div. 14.9 DER-385：255 W 80 PLUS白金级PC电源 Figure 42 – LLC Start-up. 115 VAC, 0% Load. Upper: Standby VOUT, 2 V / div. Lower: LLC VOUT, 2 V, 20 ms / div. 同步FET漏极和栅极电压 Figure 43 – LLC Sync Rect. Q1, 100% Load. Upper: SR Gate Drive, 5 V / div. Lower: SR VDRAIN, 10 V, 10 ms / div. 第57页（共70页） Figure 44 – LLC Sync Rect. Q2, 100% Load. Upper: SR Gate Drive, 5 V / div. Lower: SR VDRAIN, 10 V, 10 ms / div. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 14.10 输出纹波测量 14.10.1 纹波测量方法 For DC output ripple measurements, use a modified oscilloscope test probe to reduce spurious signals. Details of the probe modification are provided in figures below. Tie two capacitors in parallel across the probe tip of the 4987BA probe adapter. Use a 0.1 μF / 50 V ceramic capacitor and 1.0 μF / 100 V aluminum electrolytic capacitor. The aluminum-electrolytic capacitor is polarized, so always maintain proper polarity across DC outputs. Probe Ground Probe Tip Figure 45 – Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed). Figure 46 – Oscilloscope Probe with Probe Master 4987BA BNC Adapter (Modified with Wires for Probe Ground for Ripple measurement and Two Parallel Decoupling Capacitors Added). Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第58页（共70页） 22-Jan-14 14.10.2 DER-385：255 W 80 PLUS白金级PC电源 满载输出纹波结果 Figure 47 – 12 V Output Ripple, 20 mV, 5 ms / div. 14.10.3 Figure 48 – 12 V Output Ripple, 20 mV, 10 μs / div. 空载纹波结果 Figure 49 – 12 V No-Load Output Ripple, 50 mV, 10 ms / div. 第59页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 14.11 主输出负载阶跃响应 The figures below show transient response with a 10%-100%-10%, 50%-100%-50%, 75%-100%-75% and 0%-100%-0% load steps for the 12 V output. The oscilloscope was triggered using the rising edge of the load step, and averaging was used to cancel out ripple components asynchronous to the load step in order to better ascertain the load step response. Figure 50 – Output Transient Response 10%100%-10%, 2 ms / div. Upper: VOUT, 200 mV / div. Lower: ILOAD, 10 A / div. Figure 51 – Output Transient Response 50%100%-50%, 2 ms / div. Upper: VOUT, 200 mV / div. Lower: ILOAD, 10 A / div. Figure 52 – Output Transient Response 75%-100%- Figure 53 – Output Transient Response 0%-100%75%, 2 ms / div. 0%, 2 ms / div. Upper: VOUT, 100 mV / div. Upper: VOUT, 200 mV / div. Lower: ILOAD, 10 A / div. Lower: ILOAD, 10 A / div. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第60页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 14.12 待机输出负载阶跃响应 The figures below show transient response with a 10%-100%-10%, 50%-100%-50%, 75%-100%-75% and 0%-100%-0% load steps for the 12 V output. The oscilloscope was triggered using the rising edge of the load step, and averaging was used to cancel out ripple components asynchronous to the load step in order to better ascertain the load step response. Figure 54 – Output Transient Response 10%100%-10%, 5 ms / div. Upper: VOUT, 100 mV / div. Lower: ILOAD, 1 A / div. Figure 56 – Output Transient Response 75%100%-75%, 5 ms / div. Upper: VOUT, 20 mV / div. Lower: ILOAD, 1 A / div. 第61页（共70页） Figure 55 – Output Transient Response 50%100%-50%, 5 ms / div. Upper: VOUT, 50 mV / div. Lower: ILOAD, 1 A / div. Figure 57 – Output Transient Response 0%-100%0%, 5 ms / div. Upper: VOUT, 200 mV / div. Lower: ILOAD, 1 A / div. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 15 传导EMI 15.1 EMI设置 15.1.1 EMI测试的电源准备 The picture below shows the power supply set-up for EMI and surge testing. The power supply is enclosed in a metallic enclosure. Figure 58 – DER-385 Set-up for EMI and Surge Testing. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第62页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 15.1.2 EMI测试设置 Figure 59 – EMI Room Set-up. 第63页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 15.2 EMI扫描 Conducted EMI tests were performed with a resistive load on the 12 V main and standby outputs. The secondary ground of the unit was connected to the metallic enclosure with the help of a screw, which in turn was hard wired to the AC cord ground. The resistive load was left floating. Figure 60 – Conducted EMI, 115 VAC. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第64页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 Figure 61 – Conducted EMI, 230 VAC. 第65页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 16 增益相位测量 Gain-phase measurements were carried out on DER-385 at 20%, 50% and 100% loads. Figure 83 – DER-385 LLC Gain-Phase Measurement, Full Load Gain Crossover Frequency – ~7.5 kHz, Phase Margin, ~57º. Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第66页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 17 附录 17.1 中继电缆准备 第67页（共70页） Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 17.2 22-Jan-14 PFC电感装配 Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com 第68页（共70页） 22-Jan-14 DER-385：255 W 80 PLUS白金级PC电源 18 版本历史 Date 22-Jan-14 Author SS 第69页（共70页） Revision 2.1 Description and Changes Initial Release Reviewed Apps & Mktg Power Integrations 电话：+1 408 414 9200 传真：+1 408 414 9201 www.powerint.com DER-385：255 W 80 PLUS白金级PC电源 22-Jan-14 有关最新产品信息，请访问： 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, LYTSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS, HiperLCS, Qspeed, 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 2013 Power Integrations, Inc. Power Integrations 全球销售支持网络 全球总部 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] 德国 Lindwurmstrasse 114 80337, Munich Germany Phone: +49-895-527-39110 Fax: +49-895-527-39200 e-mail: [email protected] 日本 Kosei Dai-3 Building 2-12-11, Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033 Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] 台湾 5F, No. 318, Nei Hu Rd., Sec. 1 Nei Hu District Taipei 11493, Taiwan R.O.C. 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