DESIGN EXAMPLE REPORT Title 65 W Adapter Using TOP258EN Specification 90 – 265 VAC Input; 19 VDC, 3.42 A Output Application Notebook Adapter Author Applications Engineering Department Document Number DER-197 Date July 17, 2008 Revision 1.0 Summary and Features • • • • • • • Very compact, low parts-count design • Internal current limit reduction eliminates need for current limit on secondary-side • Primary side overvoltage protection (OVP) eliminates second optocoupler 700 V MOSFET reduces solution cost • Allows lower-cost Schottky output diode: 60 V, 20 A replaces 100 V, 40 A • 132 kHz operation reduces transformer size, reducing cost • Low MOSFET capacitance allows higher frequency operation without efficiency penalty Highly energy efficient • Very low no-load input power: <200 mW @ 265 VAC • High full-load efficiency: >86% • High average efficiency: >87% Excellent transient load response Hysteretic thermal protection Over-load protection with automatic recovery Latching fault protection PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 Table of Contents 1 2 3 4 Introduction.................................................................................................................4 Power Supply Specification ........................................................................................6 Schematic...................................................................................................................7 Circuit Description ......................................................................................................8 4.1 General................................................................................................................8 4.2 Energy Efficiency.................................................................................................8 4.3 Output Power Limiting with Line Voltage .............................................................8 4.4 Output Overvoltage Protection ............................................................................8 4.5 Thermal Overload Protection...............................................................................8 4.6 AC Input and EMI Filtering ..................................................................................8 4.7 TOP258EN and Primary......................................................................................9 4.8 Output Regulation ...............................................................................................9 5 PCB Layout ..............................................................................................................10 6 Bill of Materials .........................................................................................................11 7 Transformer Specification.........................................................................................12 7.1 Electrical Diagram .............................................................................................12 7.2 Electrical Specifications.....................................................................................12 7.3 Materials............................................................................................................12 7.4 Transformer Build Diagram ...............................................................................13 7.5 Transformer Construction..................................................................................14 8 Transformer Spreadsheet.........................................................................................15 9 Performance Data ....................................................................................................18 9.1 Efficiency ...........................................................................................................18 9.1.1 Active Mode CEC Measurement Data........................................................19 9.2 Output Diode Efficiency Comparison.................................................................20 9.3 No-load Input Power..........................................................................................21 9.4 Available Standby Output Power.......................................................................22 9.5 Regulation .........................................................................................................23 9.5.1 Load ...........................................................................................................23 9.5.2 Line ............................................................................................................23 10 Thermal Performance ...........................................................................................24 11 Waveforms............................................................................................................25 11.1 Drain Voltage and Current, Normal Operation...................................................25 11.2 Output Voltage Start-up Profile..........................................................................25 11.3 Drain Voltage and Current Start-up Profile ........................................................26 11.4 Load Transient Response (50% to 100% Load Step) .......................................26 11.5 Output Ripple Measurements............................................................................27 11.5.1 Ripple Measurement Technique ................................................................27 11.5.2 Measurement Results ................................................................................28 12 Control Loop Measurements.................................................................................29 12.1 115 VAC Maximum Load...................................................................................29 12.2 230 VAC Maximum Load...................................................................................30 13 Conducted EMI .....................................................................................................31 14 Revision History ....................................................................................................32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Page 3 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 1 Introduction This engineering report describes a notebook adapter power supply employing the Power Integrations® TOPSwitch®-HX TOP258EN. This power supply operates over a universal input range and provides a 19 V, 65 W output. It has been designed and tested to operate in a sealed enclosure in an external ambient temperature environment of up to 40 °C. The high voltage (700 V) rating of the MOSFET in the TOPSwitch-HX allows the transformer primary to secondary turns ratio to be increased in this design (relative to a design using a 600 V or 650 V MOSFET). This allows using a 60 V, 20 A Schottky output diode instead of a 100 V, 40 A diode; increasing efficiency and lowering cost. The TOPSwitch-HX, by design, maintains virtually constant efficiency across a very wide load range without using special operating modes to meet specific load thresholds. This optimizes performance for existing and emerging energy-efficiency regulations. Maintaining constant efficiency ensures design optimization for future energy-efficiency regulation changes without the need for redesign. The low MOSFET capacitance of TOPSwitch-HX allows a higher switching frequency without the efficiency penalty which occurs with standard discrete MOSFETs. The 132 kHz switching frequency (rather than the 70 kHz to 100 kHz frequency used for a discrete MOSFET) reduces the transformer size required, and so reduces cost. This power supply offers the following protection features: • OVP with latching shutdown • Latching open-loop protection • Auto-recovery type overload protection • Auto-restart during brownout or line sag conditions • Accurate thermal overload protection with auto-recovery, using a large hysteresis This document provides complete design details including specifications, the schematic, bill of materials, and transformer design and construction information. This information includes performance results pertaining to regulation, efficiency, standby, transient load, power-limit data, and conducted EMI immunity. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter Figure 1 – Power Supply Photograph Showing Populated PCB and Shield / Heatspreader. (9.4 cm x 4 cm x 2.2 cm) Page 5 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 2 Power Supply Specification Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Peak Output Power Efficiency Full Load Required average efficiency at 25%, 50%, 75% and 100 % of POUT Symbol Min Typ Max Units Comment VIN fLINE 90 47 265 64 0.3 VAC Hz W 3 Wire – with P.E. 50/60 VOUT1 VRIPPLE1 IOUT1 18.4 19 19.6 100 V mV A ± 5% 20 MHz bandwidth 3.42 POUT POUT_PEAK 65 W W ηCEC 87 85 % % ηES2.0 87 % η o Measured at POUT 25 C California Energy Commission (CEC) ENERGYSTAR 2008 Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950 / UL1950 Class II Safety 1 2 Surge 9.4 x 4 x 2.2 10.1 x 4.7 x 2.9 lxwxh Dimensions Ambient Temperature TAMB kV kV 0 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 50 cm o C 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω Populated PCB Case External Free convection, sea level Page 6 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 3 Schematic Figure 2 – Schematic. Page 7 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 4 Circuit Description 4.1 General This power supply employs a TOP258EN off-line switcher, (U1), in a flyback configuration. IC U1 has an integrated 700 V MOSFET and a multi-mode controller. It regulates the output by adjusting the MOSFET duty cycle, based on the current fed into its CONTROL (C) pin. 4.2 Energy Efficiency The EcoSmart feature of U1 automatically provides constant efficiency over the entire load range. It uses a proprietary Multi-cycle-modulation (MCM) function to eliminate the need for special operating modes triggered at specific loads. This simplifies circuit design since it removes the need to design for aberrant or specific operating conditions or load thresholds. 4.3 Output Power Limiting with Line Voltage Resistors R7, R8, and R9 reduce the external current limit of U1 as the line voltage increases. This allows the supply to limit the output power to <100 VA at high line while still delivering the rated output at low line, and to provide a constant output power level with changing line voltages. The combined value of line-sensing resistors R3 and R4 (4 MΏ) sets the under-voltage and overvoltage thresholds for U1. This value also sets the maximum duty cycle at specific voltages. 4.4 Output Overvoltage Protection Open-loop faults cause the output voltage to exceed the specified maximum value. To prevent excessive output voltage levels in such cases, U1 utilizes an output overvoltage shutdown function. An increase in output voltage causes an increase in the bias winding on the primary side, sensed by VR1. A sufficient rise in the bias voltage causes VR1 to conduct and a current to be injected into the Voltage (V) pin of U1. When the current exceeds 112 µA, U1 enters the overvoltage shutdown mode. This shutdown is hysteretic and attempts are made to restart the power supply at regular intervals to check if the fault condition is removed. To change this mode to a latching shutdown, reduce the value of R12 enough to cause current into the V pin to exceed 336 µA during an open-loop condition. 4.5 Thermal Overload Protection IC U1 has an integrated accurate hysteretic thermal overload protection function. When the junction temperature of U1 reaches +142 °C during a fault condition, the IC shuts down. It automatically recovers once the junction temperature has decreased by 75 °C. 4.6 AC Input and EMI Filtering Common-mode inductors L3 and L4 provide filtering on the AC input. X-capacitor C1 provides differential filtering, and resistors R1 and R2 provide safety from shock if the AC Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter is removed, by ensuring a path for C1 to discharge. Bridge rectifier D1 rectifies the AC input, and bulk capacitor C2 filters the DC. Y-capacitor C11, connected between the primary and secondary side provides commonmode filtering. 4.7 TOP258EN and Primary Capacitor C7 provides the auto-restart timing for U1. At startup this capacitor is charged through the DRAIN (D) pin. Once it is charged U1 begins to switch. Capacitor C7 stores enough energy to ensure the power supply starts up. After start-up the bias winding powers the controller via the CONTROL pin. Bypass capacitor C6 is placed as physically close as possible to U1. Resistor R13 provides compensation to the feedback loop. The clamp network formed by VR2, C4, R5, R6, and D2 limits the drain voltage (preventing spikes at MOSFET turn off) and dissipates transformer leakage inductance energy. Capacitor C4 does not discharge below the value of VR2 during low frequency operating modes to improve light load efficiency and reduce no-load input power. Resistor R6 dampens high-frequency ringing. 4.8 Output Regulation Schottky diode D5 rectifies the output. A snubber network (C12, R15) dampens ringing across the diodes and reduces high frequency conducted and radiated noise. Capacitors C13 and C14 provide output filtering. Resistors R17 and R18 provide a voltage divider and set the DC setpoint of the output. Capacitor C16 and R19 form the phase compensation for the feedback control loop. Resistor R16 limits the gain of the feedback system to ensure power supply stability throughout the range of operation. Page 9 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 5 17-Jul-08 PCB Layout Figure 3 – Printed Circuit Layout. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 6 Bill of Materials Item 1 2 Qty 1 1 Ref Des C1 C2 Description 330 nF, 275 VAC, Film, X2 120 µF, 400 V, Electrolytic, (18 x 30) Mfg Part Number LE334-M EPAG401ELL121MM30S Mfg OKAYA Nippon Chemi-Con 3 4 5 1 2 1 C4 C6 C16 C7 NCD222K1KVY5FF ECJ-2YB1H104K ELXZ160ELL470MEB5D NIC Components Corp Panasonic Nippon Chemi-Con 6 7 8 1 1 1 C8 C9 C10 ECJ-3VB1H104K ECJ-1VB1E104K EKZE500ELL220ME11D Panasonic Panasonic Nippon Chemi-Con 9 10 11 1 1 2 C11 C12 C13 C14 440LD22-R ECJ-2VB2A102K EKZE250ELL471MJ16S Vishay Panasonic Nippon Chemi-Con 12 13 1 1 C15 D1 2.2 nF, 1 kV, Disc Ceramic 100 nF, 50 V, Ceramic, X7R, 0805 47 µF, 16 V, Electrolytic, Low ESR, 500 mΩ, (5 x 11.5) 100 nF, 50 V, Ceramic, X7R, 1206 100 nF 25 V, Ceramic, X7R, 0603 22 µF, 50 V, Electrolytic, Very Low ESR, 340 mΩ, (5 x 11) 2.2 nF, Ceramic, Y1 1 nF, 100 V, Ceramic, X7R, 0805 470 µF, 25 V, Electrolytic, Very Low ESR, 38 mΩ, (10 x 16) 470 pF 50 V, Ceramic, X7R, 0603 800 V, 3 A, Bridge Rectifier, Glass Passivated ECJ-1VC1H471J 3KBP08M-E4/51 Panasonic Vishay 14 15 16 17 18 19 20 21 22 1 1 1 1 1 1 1 1 6 800 V, 1 A, Fast Recovery, 250 ns, SMA 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 100 V, 1 A, Fast Recovery, 150 ns, SMA 60 V, 20 A, Dual Schottky, TO-220AB 4 A, 250 V,Fast, TR5 Heatsink Heatsink AC Input Receptacle, 2.5 A 250 V PCB Terminal Hole, 22 AWG RS1K-13-F BAV19WS-7-F RS1B-13-F MBR2060CT 3701400041 Custom Custom PF-190 N/A Diodes, Inc Diode Inc. Diodes, Inc Vishay Wickman Power Integrations Power Integrations Rong Feng N/A 23 24 25 26 27 2 1 1 1 1 Gen Cable CLP212SG Aavid Thermalloy 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ERJ-8GEYJ225V ERJ-8GEYJ205V ERJ-8GEYJ101V CFR-50JB-150R ERJ-8GEYJ515V ERJ-8GEYJ685V ERJ-3EKF1302V ERJ-6ENF3013V ERJ-8GEYJ512V ERJ-8GEYJ6R8V ERJ-3GEYJ200V ERJ-8GEYJ330V ERJ-8ENF1001V ERJ-6ENF6812V ERJ-6ENF1002V ERJ-8GEYJ102V PMSSS 440 0031 PH YW-490-00B TOP258EN LM431AIM 48 1 U3 Wire Jumper, Insulated, 22 AWG, 0.3 in 12 mH,xA, Ferite Toroid, 4 Pin, Output 200 µH,xA, Ferite Toroid, 4 Pin, Output Nut, Hex, Kep 4-40, S ZN Cr3 plating RoHS Heatsink Hardware, Edge Clip 21N (4.7 lbs) 10 mm L x 7 mm W x 0.5 mm H 2.2 MΩ, 5%, 1/4 W, Metal Film, 1206 2 MΩ, 5%, 1/4 W, Metal Film, 1206 100 Ω, 5%, 1/4 W, Metal Film, 1206 150 Ω, 5%, 1/2 W, Carbon Film 5.1 MΩ, 5%, 1/4 W, Metal Film, 1206 6.8 MΩ, 5%, 1/4 W, Metal Film, 1206 13 kΩ, 1%, 1/16 W, Metal Film, 0603 301 Ω, 1%, 1/8 W, Metal Film, 0805 5.1 kΩ 5%, 1/4 W, Metal Film, 1206 6.8 Ω, 5%, 1/4 W, Metal Film, 1206 20 Ω, 5%, 1/10 W, Metal Film, 0603 33 Ω, 5%, 1/4 W, Metal Film, 1206 1.0 kΩ, 1%, 1/4 W, Metal Film, 1206 68.1 kΩ, 1%, 1/8 W, Metal Film, 0805 10 kΩ, 1%, 1/8 W, Metal Film, 0805 1 kΩ, 5%, 1/4 W, Metal Film, 1206 SCREW MACHINE PHIL 4-40X5/16 SS Bobbin, EE28. Vertical, Extd creepage, 10 pins TOPSwitch-HX, TNY258EN, eSIP-7C 2.495 V Shunt Regulator IC, 2%, -40 to 85C, SOT23 Optocoupler, 80 V, CTR 80-160%, 4-Mini Flat C2004-12-02 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 D2 D3 D4 D5 F1 HS1 HS2 J1 J2 J3 J6 J7 J8 J9 JP1 JP5 L3 L4 NUT1 POWR CLIP1 R1 R2 R3 R4 R11 R5 R6 R7 R8 R9 R10 R12 R13 R14 R15 R16 R17 R18 R19 SCREW1 T1 U1 U2 PC357N3TJ00F Panasonic Panasonic Panasonic Yageo Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Building Fasteners Yih-Hwa Enterprises Power Integrations National Semiconductor Sharp 49 50 1 1 VR1 VR2 18 V, 5%, 500 mW, DO-35 250 V, 600 W Pk, 5%, TVS, DO204AC (DO-15) 1N5248B-T P6KE250ARL Diode Inc. ST Page 11 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 7 Transformer Specification 7.1 Electrical Diagram WD3, WD5: Copper Shield 1 WD6: Second Half Primary 2 FL1 WD4: 19 V Output FL2 WD2: First Half Primary 3 4 WD1: Bias 5 Figure 4 – Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 1 second, 60 Hz, from Primary to Secondary 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 Pins 4-5 and secondary shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 452 µH, ±5% 1 MHz (Min.) 5 µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description 2 Core: EE28 PC44 gapped to ALG of 478 nH/T Bobbin: EE28. Vertical, extended creepage, 10 pins Magnet Wire: #32 AWG, double coated Magnet Wire: #25 AWG, double coated Triple Insulated Wire: #24 AWG, Triple Insulated Wire Tape, 3M Polyester Film, 2.0 mils thick, 9.6 mm wide Copper Foil Tape 2 mils Tape, 3M Polyester Film, 2.0 mils thick, 13 mm wide Varnish Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 36 17-Jul-08 7.4 DER-197 – TOP258EN 65 W Adapter Transformer Build Diagram 1 WD6: 15Tx2 - #25 AWG 2 1 FL2 FL1 1 2 3 5 4 WD5: 1T Copper Foil WD4: 3Tx4 - #24 TIW WD3: 1T Copper Foil (reverse wind) WD2: 16Tx2 - #25 AWG WD1: 2Tx4 - #32 AWG Figure 5 – Transformer Build Diagram. FL – Flying leads. Mark the start of the secondary winding to denote electrical polarity. Wire Tape Copper Figure 6 – WD3 and WD5 Copper Foil Preparation. Build using Items [3], [7], and [8]. Page 13 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 7.5 17-Jul-08 Transformer Construction Bobbin Preparation Quadfilar Bias Winding Basic Insulation Primary Basic Insulation Copper Shield Basic Insulation Quadfilar Secondary Winding Basic Insulation Copper Shield Basic Insulation Primary Final Assembly Primary side of the bobbin (item [2]) orients such that the pins are on the right hand side. Winding direction is clockwise. Starting at Pin 4, wind 2 quadfilar turns of item [3]. Spread turns evenly across bobbin. Finish at Pin 5. Use one layer of item [6]. Start at Pin 3. Wind 16 bifilar turns of item [4] in 2 layers. Finish on Pin 2. Use one layer of item [6]. Use the prepared copper shield. Start on pin 1. Wind 1 turn in anticlockwise direction. Place tape of item [6] first to avoid shortage. Do not terminate this winding. Use one layer of item [6] for basic insulation. Wind 3 quadrifilar turns of item [5] (about 2 layers). Spread turns evenly across bobbin. Finish on temporary pins on secondary side. After one layer of tape to secure the winding in place, cut out the connection to the temporary pins for start and finish this winding. Leave secondary winding leads as flying. Mark the starting end of the winding for identification. Use one layer of item [6] for basic insulation. Use the prepared copper shield. Wind 1 turn in clockwise direction. Place tape of item [6] first to avoid shortage. Finish on Pin 1. Use one layer of item [6]. Start at Pin 2. Wind 15 bifilar turns of item [4] in 2 layers. Finish on Pin 1. Assemble and secure core halves so that the tape wrapped E core is at the bottom of the transformer. Varnish impregnate in item [9]. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 8 Transformer Spreadsheet ACDC_TOPSwitchHX_02130 8; Rev.1.8; Copyright Power Integrations 2008 INPUT INFO ENTER APPLICATION VARIABLES VACMIN 90 VACMAX 265 fL 50 VO 19.00 PO_AVG 65.00 PO_PEAK n 0.83 Z 0.50 VB 15 tC 3.00 CIN OUTPUT 65.00 120.0 120 OUTPUT 65.00 KI TOP258EN Power Out Volts Volts Hertz Volts Watts Watts %/100 120 Volts mSecon ds uFarads Power Out Univers al / Peak 148 W / 148 W ENTER TOPSWITCH-HX VARIABLES TOPSwitch-HX TOP258 EN Chosen Device UNIT 0.48 ILIMITMIN_EXT 1.920 1.920 Amps ILIMITMAX_EXT 2.208 2.208 Amps F F fS 132000 132000 Hertz fSmin 119000 119000 Hertz fSmax 145000 145000 Hertz FF FF 10 10 Frequency (F)=132kHz, (H)=66kHz High Line Operating Mode VOR VDS F 200.00 Volts Volts VD 0.50 Volts VDB 0.70 Volts KP 0.60 PROTECTION FEATURES LINE SENSING VUV_STARTUP 101 101 Volts VOV_SHUTDOWN 490 490 Volts RLS 4.4 4.4 M-ohms TOP_HX_021308: TOPSwitch-HX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage (main) Average Output Power Peak Output Power Efficiency Estimate Loss Allocation Factor Bias Voltage Bridge Rectifier Conduction Time Estimate Input Filter Capacitor 115 Doubled/230V 195W External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Select 'H' for Half frequency 66kHz, or 'F' for Full frequency 132kHz TOPSwitch-HX Switching Frequency: Choose between 132 kHz and 66 kHz TOPSwitch-HX Minimum Switching Frequency TOPSwitch-HX Maximum Switching Frequency Full Frequency, Jitter enabled Reflected Output Voltage TOPSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.3 < KRP < 1.0 : 1.0< KDP<6.0) Minimum DC Bus Voltage at which the power supply will start-up Typical DC Bus Voltage at which power supply will shut-down (Max) Use two standard, 2.2 M-Ohm, 5% resistors in series for line sense functionality. OUTPUT OVERVOLTAGE Page 15 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 VZ 27 27 Volts RZ 5.1 5.1 k-ohms Overload Current Ratio at VMAX 1.2 1.2 Overload Current Ratio at VMIN ILIMIT_EXT_VMIN ILIMIT_EXT_VMAX RIL 1.04 1.04 1.82 1.75 12.72 1.82 1.75 12.72 A A k-ohms N/A N/A M-ohms Zener Diode rated voltage for Output Overvoltage shutdown protection Output OVP resistor. For latching shutdown use 20 ohm resistor instead OVERLOAD POWER LIMITING RPL ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EI28 EI28 Core EI28 Bobbin EI28_BOBBIN AE 0.86 Enter the desired margin to current limit at VMAX. A value of 1.2 indicates that the current limit should be 20% higher than peak primary current at VMAX Margin to current limit at low line. EI28 0.86 P/N: P/N: cm^2 4.82 4300 4.82 4300 cm nH/T^2 9.6 9.6 mm mm 3 3 DC INPUT VOLTAGE PARAMETERS VMIN VMAX 84 375 84 375 CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.73 0.73 IAVG 0.93 0.93 Amps 1.82 1.82 Amps IR 1.09 1.09 Amps IRMS 1.12 1.12 Amps TRANSFORMER PRIMARY DESIGN PARAMETERS LP 452 452 uHenrie s LP Tolerance NP NB ALG BM 5 31 2 478 3119 5 31 2 478 3119 LE AL BW M 0.00 L NS 2.00 3 IP Warning 5 Warning Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Volts Volts nH/T^2 Gauss Peak primary Current at VMIN Peak Primary Current at VMAX Current limit/Power Limiting resistor. Resistor not required. Use RIL resistor only Core Type PC40EI28-Z BE-28-1110CPL Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Minimum DC Input Voltage Maximum DC Input Voltage Maximum Duty Cycle (calculated at PO_PEAK) Average Primary Current (calculated at average output power) Peak Primary Current (calculated at Peak output power) Primary Ripple Current (calculated at average output power) Primary RMS Current (calculated at average output power) Primary Inductance Tolerance of Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns Gapped Core Effective Inductance Operating flux density should be below 3000 Gauss, Increase turns Page 16 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter OR increase core size BP 3965 3965 Gauss BAC 936 936 Gauss ur 1918 1918 LG BWE OD 0.20 19.2 0.62 0.20 19.2 0.62 mm mm mm INS 0.07 0.07 mm DIA AWG 0.55 24 0.55 24 mm AWG CM 406 406 Cmils CMA 362 362 Primary Current Density (J) 5.49 5.49 Cmils/A mp Amps/m m^2 TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 18.71 18.71 Amps ISRMS 7.01 7.01 Amps IO_PEAK 3.42 3.42 Amps IO 3.42 3.42 Amps IRIPPLE 6.12 6.12 Amps CMS 1402 1402 Cmils 18 18 AWG DIAS 1.03 1.03 mm ODS 3.20 3.20 mm INSS 1.09 1.09 mm 755 755 Volts PIVS 56 56 Volts PIVB 44 44 Volts AWGS VOLTAGE STRESS PARAMETERS VDRAIN Warning Peak Flux Density (BP<4200) at ILIMITMAX and LP_MAX. Note: Recommended values for adapters and external power supplies <=3600 Gauss AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < 500) Primary Winding Current density (3.8 < J < 9.75) Peak Secondary Current Secondary RMS Current Secondary Peak Output Current Average Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness !!! REDUCE DRAIN VOLTAGE Vdrain<680, reduce VACMAX, reduce VOR Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage Note – The very high reflected output voltage (VOR) levels in this design require special considerations, and so the following warnings can be ignored: • Peak Primary current (IP) – The margin between the peak primary current during normal operation and the worst case minimum current limit is less than recommended. Check both the transient response and control-loop bandwidth to ensure this performance is satisfactory. • Maximum flux density (BM) - Ideally this flux density should be kept below 3000 Gauss. We can ignore this warning since the AC flux is below 1000 and BP is below 4200 Gauss. Page 17 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter • 17-Jul-08 Max Drain Voltage (VDRAIN) – VDRAIN must not exceed the rated voltage of the MOSFET (700 V). The spreadsheet assumes a clamping voltage of 1.8 times VOR (360 V). This design has a lowered clamping voltage of 240 V, which ensures VDRAIN stays within specified limits. See maximum drain voltage waveforms. 9 Performance Data All measurements were performed at room temperature. 9.1 Efficiency The following efficiency data was taken at room temperature, using a 60 Hz AC input. The output voltage was measured at the end of a cable connected to the output. The cable has a DC resistance of approximately 0.1 Ώ. The unit was operated at full load for 15 minutes prior to taking the measurements. 90% 88% Efficiency (%) 85% 83% 80% 78% 75% 73% 70% 90 125 160 195 230 265 Input Voltage (VAC) Figure 7 – Efficiency vs. Input Voltage, Room Temperature, 60 Hz. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 9.1.1 Active Mode CEC Measurement Data All single output adapters, including those provided with products, for sale in California after Jan 1st, 2007, must meet the California Energy Commission (CEC) requirement for minimum active-mode efficiency, and no-load input power. The minimum active mode efficiency is defined as the average efficiency measured at 25%, 50%, 75% and 100% of rated output power, with the limit based on the nameplate output power: Nameplate Output (PO) Minimum Efficiency in Active Mode of Operation <1W ≥ 1 W to ≤ 51 W > 51 W 0.5 × PO 0.09 × ln (PO) + 0.5 [ln = natural log] 0.85 For adapters that use a single input voltage only the measurement is made at the rated single nominal input voltage (115 VAC or 230 VAC). For universal input adapters the measurement is made at both nominal input voltages (115 VAC and 230 VAC). To meet the standard, the measured average efficiency (or efficiencies for universal input supplies) must be greater than or equal to the efficiency specified by the CEC/Energy Star standard. The data below shows the results for this power supply design. Percent of Full Load 25 50 75 100 Average ENERGY STAR 2.0 CEC 2008 specified minimum average efficiency (%) Efficiency (%) 115 VAC 230 VAC 88.03 87.67 87.42 86.47 87.4 87.11 87.44 87.37 87.74 87.42 87 85 For the latest up to date information please visit the PI Green Room: http://www.powerint.com/greenroom/regulations.htm Page 19 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 9.2 Output Diode Efficiency Comparison The following table shows how using different output diodes with different ratings affects efficiency in this design. All three diodes used the same power supply unit and use the same TOP258EN device. % of Full Load 25 50 75 100 Average Energy Star 2.0 Requirement CEC 2008 Requirement * Margin (ES 2.0) MBR2060CT 60 V, 20 A Schottky Diode MBR41H100CT1 100 V, 40 A Schottky Diode B30H60G 60 V, 30 A Schottky Diode Efficiency (%) Efficiency (%) Efficiency (%) 115 VAC 88.03 87.67 87.42 86.47 87.4 230 VAC 87.11 87.44 87.37 87.74 87.42 115 VAC 87.62 87.26 86.81 86.17 86.96 230 VAC 86.25 87.21 88.04 87.20 87.18 115 VAC 87.94 88.47 88.11 87 87.88 230 VAC 87.94 87.54 89.06 89.65 88.05 87 87 87 87 87 87 85 85 85 85 85 85 0.89 0.9 0.46 0.68 1.38 1.55 * The test method specified for measuring efficiency for Energy Star 2.0 (ES 2.0 in the preceding table) rounds data to nearest percent. Using this method a measured efficiency of 86.5% would be rounded up to 87% and meets the Energy Star 2.0 87% requirement. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 9.3 No-load Input Power The unit was operated for 15 minutes prior to measurements being taken. 200 Input Power (mW) 160 120 80 40 0 90 125 160 195 230 265 Input Voltage (VAC) Figure 8 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. Page 21 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 9.4 Available Standby Output Power The chart below shows the available output power for a given level of line voltage with input power levels of 1 W, 2 W, and 3 W. The voltage measurements were taken at the end of an output cable, which had a DC resistance of approximately 0.1 Ώ. The unit was allowed to warm up prior to taking data. 3 Output Power (W) 2.5 2 1.5 1 0.5 Standby for 1 W Input Standby for 2 W Input Standby for 3 W Input 0 90 125 160 195 230 265 Input Voltage (VAC) Figure 9 – Standby Power Availability vs. Input Voltage. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 9.5 Regulation The following data was taken at room temperature, using a 60 Hz AC input. The voltage measurements were taken at the end of an output cable with a DC resistance of approximately 0.1 Ώ. 9.5.1 Load 20 Output Voltage (VDC) 18 16 115 VAC 230 VAC 14 12 10 0 0.5 1 1.5 2 2.5 3 3.5 Output Current (A) Figure 10 – Load Regulation, Room Temperature. 9.5.2 Line Output Voltage (VDC) 20 15 10 5 0 90 125 160 195 230 265 Input Voltage (VAC) Figure 11 – Line Regulation, Room Temperature, Full Load. Page 23 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 Thermal Performance The power supply was placed inside a sealed plastic case to restrict airflow. The chamber temperature was controlled to maintain a constant temperature inside the box. The supply was operated at its rated output power (65 W). To measure the device (U1) temperature, a T-type thermocouple was attached on the heatsink, very close to the tab. The output diode (D5) temperature was measured by attaching a T-type thermocouple to its tab. The transformer (T1) core temperature was measured by attaching a T-type thermocouple firmly to the outer side of the windings. Temperature (°°C) Item 90 VAC 115 VAC 230 VAC 40 25 25 Transformer (T1) 121 (110*) 102 72 TOPSwitch (U1) 109 81 104 Rectifier (D5) 120 99 99 Bridge (D1) 94 84 - Ambient *With heat spreading glue applied. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 10 Waveforms 10.1 Drain Voltage and Current, Normal Operation Figure 12 – 90 VAC, Full Load. Upper: VDRAIN, 200 V, 2 µs / div. Lower: : IDRAIN, 1.0 A / div. Figure 13 – 265 VAC, Full Load. Upper: VDRAIN, 200 V, 2 µs / div. Lower: : IDRAIN, 1.0 A / div. 10.2 Output Voltage Start-up Profile Figure 14 – Start-up Profile, 115 VAC, 3.42 A load. Page 25 of 36 Figure 15 – Start-up Profile, 230 VAC, 3.42 A load. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 10.3 Drain Voltage and Current Start-up Profile Figure 16 – 90 VAC Input and Maximum Load. Upper: VDRAIN, 100 V & 20 ms / div. Lower: IDRAIN, 1.0 A / div. Figure 17 – 265 VAC Input and Maximum Load. Upper: VDRAIN, 200 V & 20 ms / div. Lower: IDRAIN, 1.0 A / div. 10.4 Load Transient Response (50% to 100% Load Step) In the figures shown below, the oscilloscope’s signal averaging function was used to better enable viewing the load transient response. The load’s current step was used to trigger the oscilloscope to capture the waveform. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources average out, leaving only the load step response. Figure 18 – Transient Response, 115 VAC, 50100% Load Step. Top: Output Voltage. Bottom: Load Current, 1 A/div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 19 – Transient Response, 230 VAC, 50-100% Load Step. Upper: Output Voltage. Bottom Load Current, 1 A/div. Page 26 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 10.5 Output Ripple Measurements 10.5.1 Ripple Measurement Technique 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 a 1.0 µF/50 V aluminum-electrolytic capacitor. The aluminum-electrolytic capacitor is polarized, so always maintain proper polarity across DC outputs. Probe Ground Probe Tip Figure 20 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 21 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter. (Modified with wires for ripple measurement, and two parallel decoupling capacitors added) Page 27 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 10.5.2 Measurement Results Figure 22 – Ripple, 115 VAC, Full Load. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 23 – 5 V Ripple, 230 VAC, Full Load. Page 28 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 11 Control Loop Measurements The following control-loop measurements were taken at room temperature using a 60 Hz AC input and a 3.42 A load. 11.1 115 VAC Maximum Load At 115 VAC the loop crossover frequency was measured as 2 kHz. The phase and gain margins were 45º and 9 dB, respectively. Figure 24 – Gain-Phase Plot, 115 VAC, Maximum Steady-state Load. Vertical Scale: Gain = 10 dB/div, Phase = 30 °/div. Crossover Frequency = 2.0 kHz Phase Margin = 45°. Page 29 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 11.2 230 VAC Maximum Load At 230 VAC the loop crossover frequency was measured as 500 Hz. The phase and gain margins were 60º and 30 dB, respectively. Figure 25 – Gain-Phase Plot, 230 VAC, Maximum Steady-state Load. Vertical Scale: Gain = 10 dB/div, Phase = 30 °/div. Crossover Frequency = 500 Hz, Phase Margin = 60°. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter 12 Conducted EMI Figure 26 – Conducted EMI, Maximum Steady-state Load, 115 VAC, 60 Hz, EN55022 B Limits. Output was Grounded Figure 27 – Conducted EMI, Maximum Steady-state Load, 230 VAC, 60 Hz, EN55022 B Limits. Output was Grounded Page 31 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 13 Revision History Date 17-Jul-08 Author JD Revision 1.0 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Description & changes Initial Release Reviewed Page 32 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter Notes Page 33 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 Notes Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 36 17-Jul-08 DER-197 – TOP258EN 65 W Adapter Notes Page 35 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-197 – TOP258EN 65 W Adapter 17-Jul-08 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. 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