POWERINT RD6

®
RD6
®
TOPSwitch-II
USB Reference Design Board
85 to 265 VAC Input, 15W Output
Product Highlights
Low Cost Production Worthy Reference Design
• Complete self-powered USB power supply
• Supports 4 ports and hub controller
• Single sided board
• Fully assembled and tested
• Easy to evaluate and modify
• Extensive performance data
• Over 69% efficiency
2.13 in.
(54 mm)
4.29 in. (109 mm)
Fully Protected by TOPSwitch-II
• Primary safety current limit
• Output short circuit protection
• Thermal shutdown protects entire supply
Designed for World Wide Operation
• Designed for IEC/UL safety requirements
• Meets VDE Class B EMI specifications
1.07 in.
(27 mm)
PI-2167-012098
Figure 1. RD6 Overall Physical Dimensions.
PARAMETER
Description
The RD6 reference design board is an example of a low cost
production worthy design for a self-powered, 4-port USB hub.
The design is a complete solution for powering hubs found in
products such as monitors and printers. A total of 15 W of
power is delivered through two outputs. The main output
supplies 3 A at 5 V. This meets the USB specification of
500 mA for each port (4 port total) with additional power
available for a 5 V hub controller. A second 3.3 V (100 mA)
output provides power for low voltage hub controllers.
The RD6 utilizes the TOP223Y member of the TOPSwitch-II
family of Three-terminal Off-line PWM Switchers from
Power Integrations. It is intended to help TOPSwitch users to
develop their products quickly by providing a production
ready design which needs little or no modification to meet
system requirements.
Input Voltage Range
Input Frequency Range
LIMITS
85 to 265 VAC
47 to 440 Hz
Temperature Range
0 to 70° C
Output Voltage (Io = 3.0 A)
5 V ± 4%
3.3 V ± 3%
(Io = 0.1 A)
Output Power (continuous)
15 W
Output Power (peak)
30 W
Line Regulation (85-265 VAC)
± 0.7%
Load Regulation (0%-100%)
± 1.1%
69% (min)
Efficiency
Output Ripple Voltage
Safety
EMI
5V ± 40 mV MAX
3.3V ± 25 mV MAX
IEC 950 / UL1950
VDE B (VFG243 B)
CISPR22
Figure 2. Table of Key Electrical Parameters.
March 1998
RD6
C11
470 pF
1
7, 8
VR1
P6KE200
5, 6
L2
22 mH
BR1
600 V
D1
UF4005
2
J1
D
F1
3.15 A
S
5V
C2
560 µF
35 V
U1
TOP223Y
C10
560 µF
35 V
C3
220 µF
35 V
C4
0.1 µF
R6
16 Ω
1/2 W
3.3 V
R2
47 Ω
R4
3 KΩ
3
T1
C
C5
47 µF
RTN
R1
4.7 Ω
4
TOPSwitch-II
CONTROL
L1
3.3 µH
D2
MBR1045
D3
1N4148
C1
47 µF
400 V
C6
0.1 µF
250 VAC
R12
15 Ω
R3
6.8 Ω
C7
1 nF
250 VAC
Y1
L
C8
10 nF
U2
PC817A
VR2
IN5228C
3.9 V
R5
10 KΩ
C9
220 µF
35 V
U3
TL431
N
PI-2135-030998
Figure 3. Schematic Diagram of the 15 W RD6 Power Supply.
BR1
C1
D2
T1
DC-
+3.3V GND +5V
L2
C6
C3
R12
L1
C11
J2
VR1
C2
D1
U1
F1
C4
J1
HS1
POWER INTEGRATIONS INC.
RD6 REV. A
S/N
C5 R3
R6
C10
C7
VR2
R2
D3
U2
R1 U3 C8
R5
R4
C9
COMPONENT SIDE SHOWN
PI-2137-122297
Figure 4. Component Legend of the RD6.
General Circuit Description
The RD6 is a low-cost flyback switching power supply using
the TOP223Y integrated circuit. The circuit shown in Figure 3
details a 5 V, 15 W power supply that operates from 85 to
265 VAC input voltage, suitable for powering a USB hub with
as many as 4 ports, and a 3.3 V, 100 mA auxiliary output for
powering a hub controller. AC power is rectified and filtered
by BR1 and C1 to create the high voltage DC bus applied to the
primary winding of T1. The other side of the transformer
primary is driven by the integrated high-voltage MOSFET
2
B
3/98
within the TOP223. D1 and VR1 clamp the voltage spike
caused by transformer leakage inductance to a safe value and
reduce ringing. The power secondary winding is rectified and
filtered by D2, C2, C10, L1, and C3 to create the 5 V output
voltage. The 5 V output is directly sensed by optocoupler U2
and Zener diode VR2. The output voltage is determined by the
Zener diode VR2 plus the voltage drops across the LED of the
optocoupler U2 and resistor R1. Other output voltages are also
possible by adjusting the transformer turns ratios and the value
RD6
Component Listing
Reference
Value
BR1
C1
C2, C10
C3, C9
C4
C5
C6
C7
600 V, 2 A
47 µF, 400 V
560 µF, 35 V
220 µF, 35 V
0.1 µF, 50 V
47 µF, 10 V
0.1 µF, 250 VAC, X2
1.0 nF, 250 VAC, Y1*
C8
C11
D1
D2
D3
L1
L2
R1
R2
R3
R4
R5
R6
R12
T1**
U1
U2
U3
VR1
VR2
F1
Part Number
2KBPC06M
ECA-2GG470YE
ECA-1VFQ561
ECE-1AVGE221
RPE121Z5U104M50V
ECE-A1AG470
F1772-410-2000
WKP102MCPE.OK
DE1110E102M ACT4K-KD
440LD10
10 nF, 50 V
RPE110Z5U103M50V
470 pF, 50 V
RPE110X7R471K50V
600 V, 1 A, UFR
UF4005
45 V, 10 A Schottky
MBR1045
75 V, Switching
1N4148
3.3 µH, 5.5 A
6000-3R3M
22 µH, 0.4 A
ELF-18D290C
4.7 Ω, 1/4 W
5043CX4R700J
47 Ω, 1/4 W
5043CX47R00J
6.8 Ω, 1/4 W
5043CX6R800J
3.16 KΩ, 1/4 W, 1%
5043EM3K160F
10.0 KΩ, 1/4 W, 1%
5043EM10K00F
16 Ω, 1/2 W
5053CX16R00J
15 Ω, 1/4 W
5043CX15R00J
TRD6
TOP223Y
Optocoupler, Controlled CTR PC817A
Adj. Shunt Regulator
TL431CLP
200 V Zener TVS
P6KE200
3.9 V 2% Zener
1N5228C
3.15 A, 250 VAC
19372, 3.15A
Manufacturer
General Instrument
Panasonic
Panasonic
Panasonic
Murata
Panasonic
Roederstein
Roederstein
Murata
Cera-Mite
Murata
Murata
General Instrument
Motorola
National Semiconductor
J. W. Miller
Panasonic
Philips
Philips
Philips
Philips
Philips
Philips
Philips
Custom
Power Integrations
Sharp
Motorola
Motorola
APD
Wickman
Figure 5. Parts List for the RD6 (* Two Series-Connected 2.2 nF, Y2 Capaciors such as Murata P/N DE7100F222MVA1-KC can replace
C7) ** T1 is available from Premier Magnetics (714) 362-4211 as P/N TSD-1106, and from Coiltronics (561) 241-7876 as P/N CTX14-13598
of Zener diode VR2. The 3.3 V output is derived from the 5 V
output using R6 and shunt regulator U3. C11 and R12 form a
snubber circuit across D2 to reduce ringing. This improves
conducted RFI performance of the supply at high frequency
(15-20 MHz) and reduces leakage spikes, improving the
reliability of D2. R2 provides bias current for Zener VR2 to
improve regulation.
The primary bias winding is rectified and filtered by D3 and C4
to create a bias voltage to power the TOP223Y. L2 and
Y1-capacitor C7 attenuate common-mode emission currents
caused by high-voltage switching waveforms on the DRAIN
side of the primary winding and the primary to secondary
capacitance. L2 and C6 attenuate differential-mode emission
currents caused by the fundamental and harmonics of the
primary current waveform. C5 filters internal MOSFET gate
drive charge current spikes on the CONTROL pin, determines
the auto-restart frequency, and together with R1 and R3,
compensates the 5 V control loop. R6 and shunt regulator U3
are used to derive a 3.3 V supply from the 5V output. R4 and
R5, along with the 2.5 V internal band gap reference in U3, are
used to set the output voltage. C8 provides compensation for
the 3.3 V control loop. C9 provides additional filtering for the
3.3 V output. As a shunt regulator, U3 provides a constant load
of approximately 100 mA on the 5 V output, regardless of
whether a load is present on the 3.3 V output. This provides a
substantial preload for the 5 V output, greatly improving
regulation at light or zero load. The circuit performance data
shown in Figures 6-21 were measured with AC voltage applied
to the RD6.
Load Regulation (Figure 6) – The change in the DC output
voltage for a given change in output current is referred to as
load regulation. Both the 5 V and 3.3 V outputs stay within
B
3/98
3
RD6
General Circuit Description (cont.)
±1.1 % of nominal from 0% to 100% of rated load current. The
TOPSwitch on–chip over-temperature protection circuit will
safely shut down the power supply under persistent overload
conditions.
15 for the same test condition Line frequency and switching
frequency ripple for the 3.3 V output are shown in Figures 17
and 18, respectively.
Line Regulation (Figure 7) - The change in the DC output
voltage for a given change in the AC input voltage is called line
regulation. The maximum change in output voltage vs line for
both the 5 V and 3.3 V outputs is within ± 0.7%.
The 5 V output transient response to a step load change from
2.25 to 3 A (75% to 100%) is shown in Figure 19. Note that the
response is quick and well damped. The initial voltage spike in
response to the load step is due to the interaction of the load
current with the ESR of C3. If desired, the amplitude of this
spike can be reduced by substituting a low ESR capcitor for C3.
Efficiency (Load Dependent) – The curves in Figures 10 and
11 show how the efficiency changes with output power for
115 VAC and 230 VAC inputs.
Power Supply Turn On Sequence – The internal switched,
high-voltage current source provides the initial bias current for
TOPSwitch when power is first applied. The waveforms
shown in Figure 12 illustrate the relationship between the
high-voltage DC bus and the 12 V output voltage. Capacitor
C1 charges to the peak of the AC input voltage before TOPSwitch
turns on. The delay of 150 ms (typical) is caused by the time
required to charge the auto-restart capacitor C5 to 5.8 V. At
this point the power supply turns on as shown.
Figure 13 shows the 5 V output turn on transient as well as a
family of curves associated with an additional soft-start
capacitor. The soft-start capacitor is placed across VR2 and
can range in value from 10 uF to 47 uF as shown.
Line frequency ripple voltage for the 5 V output is shown in
Figure 14 for 115 VAC input and 15 W output. Switching
frequency ripple voltage on the 5 V output is shown in Figure
The RD6 is designed to meet worldwide safety and EMI (VDE
B) specifications. Measured conduction emissions are shown
in Figure 20 for 115 VAC and Figure 21 for 230 VAC.
Transformer Specification
The electrical specifications and construction details for
transformer TRD6 are shown in Figures 22 and 23. Transformer
TRD6 is supplied with the RD6 reference design board. This
design utilizes an EI25 core and a triple insulated wire
secondary winding. The use of triple insulated wire allows the
transformer to be constructed using a smaller core and bobbin
than a conventional magnet wire design due to the elimination
of the margins required for safety spacing in a conventional
design.
If a conventional margin wound transformer is desired, the
design of Figures 24-25 can be used. This design (TRD6-1)
uses a EEL22 core and bobbin to accommodate the 3 mm
margins required to meet international safety standards when
using magnet wire rather than triple insulated wire, and has the
same pinout and printed circuit foot print as TRD6. The
transformer is approximately 50% taller than the triple
insulated wire design due to the inclusion of creepage margins
required to meet international safety standards.
105
VIN = 115 VAC
100
95
0
1.0
2.0
3.0
Load Current (A)
105
VIN = 230 VAC
100
95
0
1.0
2.0
3.3V Output Voltage (% of Nominal)
5V Output Voltage (% of Nominal)
105
3.0
Figure 6. Load Regulation
B
3/98
100
95
0
0.5
0.1
Load Current (A)
105
VIN = 230 VAC
100
95
0
0.5
Load Current (A)
Load Current (A)
4
VIN = 115 VAC
PI-2147-012398
Efficiency (Line Dependent) – Efficiency is the ratio of the
output power to the input power. The curves in Figures 8 and 9
show how the efficiency changes with input voltage.
0.1
5V @ 3.0A and 3.3V @ 0.1A
100
95
50
100
150
200
250
300
Input Voltage (VAC)
105
5V @ 0.53A and 3.3V @ 0.1A
100
95
50
100
150
200
250
105
5V @ 3.0A and 3.3V @ 0.1A
100
95
50
100
150
200
250
PI-2151-011598
105
3.3V Output Voltage (% of Nominal)
5V Output Voltage (% of Nominal)
RD6
300
Input Voltage (VAC)
105
5V @ 0.53A and 3.3V @ 0.1A
100
95
300
50
100
150
200
250
300
Input Voltage (VAC)
Input Voltage (VAC)
Figure 7. Line Regulation
60
40
20
0
80
60
40
20
0
100
200
300
0
100
Input Voltage (VAC)
80
60
40
20
100
VIN = 230 VAC
Output Efficiency (%)
PI-2159-011598
VIN = 115 VAC
300
Figure 9. Efficiency vs. Input Voltage, 3 W Output
Figure 8. Efficiency vs. Input Voltage, 15.3 W Output
100
200
Input Voltage (VAC)
PI-2161-011598
0
Output Efficiency (%)
PI-2157-011598
80
Po = 3 W
Output Efficiency (%)
Po = 15.3 W
Output Efficiency (%)
100
PI-2153-011598
100
80
60
40
20
0
0
0
5
10
15
20
Output Power (W)
Figure 10. Output Efficiency vs. Output Power, 115 VAC Input
0
5
10
15
20
Output Power (W)
Figure 11. Output Efficiency vs. Output Power, 230 VAC Input
B
3/98
5
PI-2165-011998
DC BUS VOLTAGE
150
PI-2163-011998
RD6
Output Voltage (V)
100
50
0
OUTPUT
VOLTAGE
6
4
0 µF
4
22 µF
0
0
200
0
80
PI-2169-012098
60
60
Output Voltage (mV)
40
20
0
-20
-40
-60
40
20
0
-20
-40
-60
-80
-80
25
0
50
0
Time (ms)
60
40
20
0
-20
-40
50
80
PI-2175-012098
PI-2173-012098
80
25
Time (µs)
Figure 15. 5 V Switching Frequency Ripple, 115 VAC Input, 15.3 W Output
60
Output Voltage (mV)
Figure 14. 5V LineFrequency Ripple, 115 VAC Input, 15.3 W Output
40
20
0
-20
-40
-60
-60
-80
-80
0
25
50
Time (ms)
Figure 16. 3.3 V Line Frequency Ripple, 115 VAC Input, 15.3 W Output
6
200
Time (ms)
Figure 13. Output Voltage Turn On Transient vs Soft Start Capacitor
Time (ms)
Figure 12. Turn On Delay
80
100
PI-2171-012098
100
0
Output Voltage (mV)
10 µF
47 µF
2
2
Output Voltage (mV)
6
B
3/98
0
25
Time (µs)
50
Figure 17. 3.3 V Switching Frequency Ripple, 115 VAC Input, 15.3 W Output
RD6
PI-2177-012198
40
Output Current (A) Output Voltage (mV)
20
0
-20
-40
-60
3.0
2.0
1.0
0
10
20
Time (ms)
Amplitude (dBmV)
Amplitude (dBmV)
80
60
40
20
VDE B Limit
(VFG243A)
100
PI-2181-012398
VDE B Limit
(VFG243A)
100
PI-2179-012398
Figure 19. 5 V Transient Load Response (75% to 100% Load)
80
60
40
20
0
0
0.01
0.1
1
10
Frequency (MHz)
Figure 20. EMI Characteristics at 115 VAC Input
0.01
0.1
1
10
Frequency (MHz)
Figure 21. EMI Characteristics at 230 VAC Input
B
3/98
7
RD6
8
5
1
4
1
62 T
#30 AWG
PIN
1
2
3
4
5, 6
7, 8
7, 8
3T
4x #24 AWG
Triple-insulated
2
3
7T
2x #30 AWG
5, 6
FUNCTION
HIGH-VOLTAGE DC BUS
TOPSwitch DRAIN
PRIMARY-SIDE COMMON
VBIAS
RETURN
OUTPUT
4
CORE# - PC40 EI25-Z (TDK)
GAP FOR AL OF 245 nH/T2
BOBBIN# - BE-25-118CP (TDK)
ELECTRICAL SPECIFICATIONS
Electrical Strength
60 Hz, 1 minute,
from pins 1-4 to pins 5-8
3000 VAC
Creepage
Between pins 1-4 and pins 5-8
6.0 mm (min)
Primary Inductance
Between Pins 1-2 (All other windings open)
980 µH, ±10%
Resonant Frequency
Between Pins 1-2 (All other windings open)
700 KHz (min)
Primary Leakage Inductance
Between Pins 1-2 (Pins 5-8 shorted)
40 µH (max)
NOTE: All inductance measurements should be made at 100 kHz
PI-2139-121897
Figure 22. Electrical specification of transformer TRD6
8
B
3/98
RD6
TAPE
5
6
8
7
3
4
1
2
SECONDARY
BIAS
PRIMARY
WINDING INSTRUCTIONS
Primary (2 layers)
Start at pin 2. Wind 62 turns of #30 AWG heavy nyleze
magnet wire in two layers. Finish on Pin 1
Basic Insulation
1 layer of 10.8 mm wide polyester tape for basic insulation.
Bifilar Bias Winding
Start at Pin 4. Wind 7 turns of 2 parallel strands of
#30 AWG heavy nyleze magnet wire. Space turns evenly
across bobbin to form a single layer. Finish on Pin 3.
Basic Insulation
1 layer of 10.8 mm wide polyester tape for basic insulation.
24 V Double Bifilar
Secondary Winding
Start at Pins 7 and 8. Wind 3 quadrifilar turns of #24 AWG
Triple Insulated Wire. Finish on Pins 5 and 6.
Outer Insulation
3 layers of 10.8 mm wide polyester tape for insulation.
Final Assembly
Assemble and secure core halves. Impregnate
uniformly using varnish.
* Triple insulated wire sources.
P/N: T28A01TXXX-3
Rubudue Wire Company
5150 E. La Palma Avenue
Suite 108
Anaheim Hills, CA 92807
(714) 693-5512
(714) 693-5515 FAX
P/N: order by description
Furukawa Electric America, Inc.
200 Westpark Drive
Suite 190
Peachtree City, GA 30269
(770) 487-1234
(770) 487-9910 FAX
P/N: order by description
The Furukawa Electric Co., Ltd
6-1, Marunouchi 2-chome,
Chiyoda-ku, Tokyo 100, Japan
81-3-3286-3226
81-3-3286-3747 FAX
PI-2145-121897
Figure 23. Construction details of transformer TRD6
B
3/98
9
RD6
8
5
1
4
1
62 T
#30 AWG
PIN
1
2
3
4
5, 6
7, 8
7, 8
3T
4x #24 AWG
2
3
7T
2x #30 AWG
5, 6
FUNCTION
HIGH-VOLTAGE DC BUS
TOPSwitch DRAIN
PRIMARY-SIDE COMMON
VBIAS
RETURN
OUTPUT
4
CORE# - PC40 EE22/29/6-Z (TDK)
GAP FOR AL OF 145 nH/T2
BOBBIN# - YC 2204 (Ying Chin)
ELECTRICAL SPECIFICATIONS
Electrical Strength
60 Hz, 1 minute,
from pins 1-4 to pins 5-8
3000 VAC
Creepage
Between pins 1-4 and pins 5-8
6.0 mm (min)
Primary Inductance
Between Pins 1-2 (All other windings open)
840 µH, ±10%
Resonant Frequency
Between Pins 1-2 (All other windings open)
700 KHz (min)
Primary Leakage Inductance
Between Pins 1-2 (Pins 5-8 shorted)
40 µH (max)
NOTE: All inductance measurements should be made at 100 kHz
PI-2143-121897
Figure 24. Electrical specification of transformer TRD6-1
10
B
3/98
RD6
5, 6
7, 8
3
4
TAPE
1
2
SLEEVING
SECONDARY
BIAS
TAPE MARGINS
PRIMARY
WINDING INSTRUCTIONS
Primary Margins
Tape margins with 3 mm wide polyester tape. Match height with primary
and bias windings.
Primary Windings
Start at pin 2. Wind one layer (approximately 38 turns) of 30 AWG
heavy nyleze magnet wire from bottom (pin side) to top. Use one layer
of 12.2 mm wide polyester tape over first primary layer for basic
insulation. Continue winding remaining primary turns from top to bottom.
Finish on Pin 1. Sleeve start and finish with 24 AWG Teflon sleeving.
Basic Insulation
Bias Winding
Use 1 layer of 12.2 mm wide tape for basic insulation.
Start at Pin 4. Wind 7 bifilar turns 30 AWG heavy nyleze magnet wire
from bottom to top. Spread turns evenly across bobbin. Finish on Pin 3.
Sleeve start and finish leads with 24 AWG Teflon sleeving.
Reinforced Insulation
Use 3 layers of 18.2 mm wide polyester tape for reinforced insulation.
Secondary Windings
Tape margins with 3 mm wide polyester tape. Match height with
secondary winding.
12V Secondary Winding
Start at Pins 7 and 8. Wind 3 quadrifilar turns of 24 AWG heavy nyleze
magnet wire from bottom to top. Spread turns evenly across bobbin.
Finish on Pins 5 and 6. Sleeve start and finish leads with 24 AWG
Teflon sleeving.
Outer Insulation
Apply 3 layers of 18.2 mm wide polyester tape for outer insulation.
Final Assembly
Assemble and secure core halves. Impregnate uniformly with varnish.
PI-2141-121897
Figure 25. Construction details of transformer TRD6-1
B
3/98
11
RD6
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, nor does it
convey any license under its patent rights or the rights of others.
PI Logo and TOPSwitch are registered trademarks of Power Integrations, Inc.
©Copyright 1998, Power Integrations, Inc. 477 N. Mathilda Avenue, Sunnyvale, CA 94086 http://www.powerint.com
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+1•408•523•9265
Fax:
+1•408•523•9365
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Phone:
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12
B
3/98
INDIA (Technical Support)
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Phone:
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Fax:
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