View DER-44_1232163.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

Design Example Report
Title 41W (53Wpk) Power Supply using TOP246Y
Input: 85 - 265 VAC Specification Output: 30V/80mA, 23V/0.5A, 12V/2A, 5V/2A, 3.3V/1.5A Application Author Document Number Date Revision Digital Video Recorder Power Integrations Applications Department DER-44 March 7, 2005 1.0
Summary and Features * * * * * * No linear regulators used One transformer solution Good cross regulation No heatsinks used in secondary Low cost OVP using TO-92 SCR crowbar Low EMI with low-cost EMI filter
The products and applications illustrated herein (including circuits external to the products and transformer construction) 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 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
Table Of Contents
1 2 3 4 5 Introduction ................................................................................................................... 4 Photograph.................................................................................................................... 4 Power Supply Specification........................................................................................... 5 Schematic ..................................................................................................................... 6 Circuit Description ......................................................................................................... 7 5.1 Input EMI Filtering .................................................................................................. 7 5.2 TOPSwitch Primary................................................................................................ 7 5.3 Outputs................................................................................................................... 7 5.4 Output Feedback.................................................................................................... 7 5.5 Output OV Protection ............................................................................................. 7 6 PCB Layout ................................................................................................................... 8 7 Bill Of Materials ............................................................................................................. 9 8 Transformer Specification ........................................................................................... 11 8.1 Electrical Diagram ................................................................................................ 11 8.2 Electrical Specifications ....................................................................................... 11 8.3 Materials............................................................................................................... 12 8.4 Transformer Build Diagram .................................................................................. 12 8.4.1 WD#3 Copper Foil build diagram: ................................................................. 13 8.4.2 WDG#4 & #5 Copper Foil build diagram: ...................................................... 13 8.5 Transformer Construction..................................................................................... 14 8.6 Transformer Spreadsheets................................................................................... 15 9 Performance Data ....................................................................................................... 18 9.1 Line and Load Regulation .................................................................................... 18 9.2 Efficiency.............................................................................................................. 19 9.3 Overvoltage Protection......................................................................................... 19 10 Thermal Performance .............................................................................................. 20 11 Control Loop Measurements.................................................................................... 21 11.1 110 VAC Maximum Continuous Load .................................................................. 21 11.2 230 VAC Maximum Continuous Load .................................................................. 21 12 Waveforms............................................................................................................... 22 12.1 Drain Voltage and Current, Normal Operation ..................................................... 22 12.2 Output Voltage Start-up Profile ............................................................................ 22 12.3 Drain Voltage Start-up Profile............................................................................... 23 13 Output Ripple Measurements .................................................................................. 24 13.1.1 Ripple Measurement Technique ................................................................... 24 13.1.2 Measurement Results ................................................................................... 25 14 Conducted EMI ........................................................................................................ 28 14.1 230V High Line EMI ............................................................................................. 28 15 Revision History....................................................................................................... 29
Page 2 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
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. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
Page 3 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
1 Introduction
This document is an engineering report describing a PSU design using TOP246Y. The design adopts a one transformer solution, meets EMI and peak power with good margin. The use of a smaller transformer is made possible by TOPSwitch-GX's high switching frequency with good switching performance, and the low EMI with a low-cost filter is made possible because of TOPSwitch-GX's frequency jitter and E-ShieldTM transformer winding techniques. This document contains the power supply specifications, schematic, Bill of materials, transformer documentation, printed circuit layout, and performance data.
2 Photograph
Figure 1 - Circuit Board Photograph.
Page 4 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
3 Power Supply Specification
Description Input Voltage Frequency Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Output Voltage 3 Output Ripple Voltage 3 Output Current 3 Output Voltage 4 (FL) Output Ripple Voltage 4 Output Current 4 Output Voltage 5 Output Ripple Voltage 5 Output Current 5 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Safety Ambient Temperature TAMB Symbol VIN fLINE VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 VOUT5 VRIPPLE5 IOUT5 POUT POUT_PEAK 72.8 28.5 21.85 11.4 4.75 Min 90 47 3.135 Typ Max 265 64 3.465 Units VAC Hz V mV A 5.25 V mV A 12.6 V mV A 24.15 V mV A 31.5 V mV A
+/- 5% 20 MHz Bandwidth for all the outputs +/- 5% 20 MHz Bandwidth for all the outputs +/- 5% 20 MHz Bandwidth for all the outputs +/- 5% 20 MHz Bandwidth for all the outputs
Comment
2 Wires System
50/60 3.3 1.5 5.0 2 12 2 23 0.5 30 0.08
+/- 5% 20 MHz Bandwidth for all the outputs
41 53
W W %
Actual load measurement Measured at 230VAC, POUT (41W), 25 oC
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
25
o
C
Free convection, sea level
The power supply is designed to meet 53W output power for a short period - a few minutes. The output power is only thermally limited by the heatsink attached to the TOP246Y. In the currently sized heatsink (80 x 35 x 3 mm), the continuous output power is 41W.
Page 5 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
4 Schematic
Figure 2 - Schematic Note: C33, C34, C16, R51, R52, R53, Q2 and VR10 are added to the PCB bottom side.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 6 of 30
DER-44
41W (53W pk) DVR
March 7, 2005
5 Circuit Description
The schematic in Figure 2 shows an off-line flyback converter using the TOP246Y. The circuit is designed for 85 VAC to 265 VAC. 5.1 Input EMI Filtering X-capacitor C32, and common-mode choke L1 act as an input filter to reduce common mode and differential mode EMI. The AC line voltage is rectified and filtered to generate a high voltage DC bus via D1-4 and C1. 5.2 TOPSwitch Primary Diode D5, C6, and R4, R45 and VR5 clamp leakage spikes generated when the MOSFET when U1 switches off. D5 is a glass-passivated normal recovery rectifier. The slow, controlled recovery time of D5 allows energy stored in C6 to be recycled back to the high voltage bus, significantly increasing efficiency. A normal (non-glass-passivated) 1N4007 should not be substituted for the glass-passivated device. C5 bypasses the U1 control pin. C4 has three functions. It provides the energy required by U1 during startup, sets the autorestart frequency during fault conditions, and also acts to roll off the gain of U1 as a function of frequency. R8 adds a zero to the control loop to help stabilize the power supply control loop. Diode D6 and capacitor C3 provide rectified and filtered bias power for U1 and U2. Components R39, R48 and R9 provide a signal to the U1 X pin to reduce current limit at high line to keep the maximum output power consistent with low line. R47 and R38 provide OV/UV protection. 5.3 Outputs The T1 output is rectified and filtered by Diodes D8-D12 and filtered by inductor/capacitor networks on most outputs. NOTE: Large capacitors were used for the 12V output in order to prevent possible voltage overshoots from the reverse current coming from the Hard Disk Drive motor. Testing with the actual unit may show that these capacitors can be reduced for cost reduction. 5.4 Output Feedback Output feedback is used from a combination of the 5 V and the 3.3 V rails. Resistors R31, R32 and R30 develop a feedback voltage, which is fed to the reference regulator U3. U3 drives optocoupler U2 through resistor R27 to provide feedback information to the U1 control pin. The optocoupler output also provides power to U1 during normal operating conditions. Capacitor C7 applies drive to the optocoupler during supply startup to reduce output voltage overshoot. Capacitor C21 and R29 provide frequency compensation for error amplifier U3. 5.5 Output OV Protection Q2 is positioned across the 30V output winding; upon OV on the 5V, detected by VR10, Q2 will be triggered ON to short the 30V winding. The PS will go into auto-restart mode until the OV fault is removed.
Page 7 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
6 PCB Layout
Figure 3 - Printed Circuit Layout
Note: Q1, D7, R31, R33, R50, C15, VR6, VR7, VR8 and VR9 are not stuffed on the PCB. C33, C34, C16, R51, R52, R53, Q2 and VR10 are added to the PCB and mounted on the bottom side of the PCB
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 8 of 30
DER-44
41W (53W pk) DVR
March 7, 2005
7 Bill Of Materials
Item 1 Qua. Value 1 150 uF Part Ref. C1 Description 150 uF, 400 V, Electrolytic, Low ESR, 410 mOhm, (16 x 60) 2 3 22 uF C3 C8 C9 Mfg Part Number Mfg KMX400VB151M16X60L United Chemi-Con L United Chemi-Con
22 uF, 50 V, Electrolytic, Very Low ESR, 340 mOhm, (5 x KZE50VB22RME11LL 11)
3 4 5 6
2 100 uF 2 100 nF 2 1 nF 1 220 uF
C4 C7 C5 C21 C6 C34 C10
100 uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) 100 nF, 50 V, Ceramic, X7R 1 nF, 1 kV, Disc Ceramic
KME10VB101M5X11LL ECU-S1H104KBB NCD102K1KVY5F
United Chemi-Con Panasonic NIC Components Corp United Chemi-Con
220 uF, 35 V, Electrolytic, Very Low ESR, 56 mOhm, (8 x KZE35VB221MH15LL 15)
7
1 1000 uF
C11
1000 uF, 25 V, Electrolytic, Very Low ESR, 21 mOhm, (12.5 x 20)
KZE25VB102MK20LL
United Chemi-Con
8
1 2200 uF
C12
2200 uF, 10 V, Electrolytic, Very Low ESR, 21 mOhm, (12.5 x 20)
KZE10VB222MK20LL
United Chemi-Con
9
1 1200 uF
C13
1200 uF, 10 V, Electrolytic, Very Low ESR, 23 mOhm, (10 KZE10VB122MJ20LL x 20)
United Chemi-Con
10
2 220 uF
C14 C24
220 uF, 10 V, Electrolytic, Low ESR, 250 mOhm, (6.3 x 11.5)
LXZ10VB221MF11LL
United Chemi-Con
11 12
1 10 nF 2 2700 uF
C16 C22 C25
10 nF, 50 V, Film
ECQ-V1H103JL3
Panasonic United Chemi-Con
2700 uF, 25 V, Electrolytic, Very Low ESR, 16 mOhm, (16 KZE25VB272ML25LL x 25)
13
1 33 uF
C23
33 uF, 35 V, Electrolytic, Very Low ESR, 300 mOhm, (5 x KZE35VB33RME11LL 11)
United Chemi-Con
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2.2 nF 1 330 nF 1 100 pF 4 1N4007 1 1N4007GP 1 BAV20 1 BYV26B 1 SB560 1 SB540 1 UF4004 1 SB5100 2 1N4001 1 1N5817 1 2A 1 1.560H x 0.080W x 2.675L
C31 C32 C33
2.2 nF, Ceramic, Y1 Safety X capacitor, 270V 100 pF, 1 kV, Disc Ceramic
440LD22 Any NCD101K1KVY5F 1N4007 1N4007GP BAV20 BYV26B SB560 SB540 UF4004 SB5100 1N4001 1N5817 3,721,200,041
Vishay
NIC Components Corp Vishay Vishay Vishay Philips Vishay Vishay Vishay Fairchild Vishay Vishay Wickman
D1 D2 D3 D4 1000 V, 1 A, Rectifier, DO-41 D5 D6 D8 D9 D10 D11 D12 D13 D15 D14 F1 HS1 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 200 V, 200 mA, Fast Switching, 50 ns, DO-35 400 V, 1 A, Ultrafast Recovery, 30 ns, SOD57 60 V, 5 A, Schottky, DO-201AD 40 V, 5 A, Schottky, DO-201AD 400 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 100 V, 5 A, Schottky, DO-201AD1 50 V, 1 A, Rectifier, DO-41 20 V, 1 A, Schottky, DO-41 2 A,250V, Slow, TR5 Heatsink, Custom, Vestel, L Shaped
29 30 31 32 33
1 CON3 1 CON8 1 CON4 1 6.2 mH 5 3.3 uH
J9 J10 J11 L1 L2 L3 L4 L5 L6
AC Input Receptacle and Accessory Plug, PCBM 8 Position (1 x 8) header, 0.1 pitch, Vertical 4 Position (1 x 4) header, 0.1 pitch, Vertical 6.2 mH, 1 A, Common Mode Choke 3.3 uH, 2.66 A
161-R301SN13 22-28-4080 22-28-4049 Any 822LY-3R3M
Kobiconn Molex Molex Any Toko
34
4 Mounting Holes
M1 M2 M3 M4 PCB Terminal Hole
N/A
N/A
35
1 MCR2206
Q2
400V, 1.5A SCR
N/A
N/A
Page 9 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 1 47 k 1 240 1 10 2 6.8 1 6.81 k 2 68 1 1k 1 20 k 1 10 k 1 DNP 1 30.9 k 2 1M 2 8.2 M 1 30 2 560 k 1 2k 1 100 15 1 320 Vac 1 EER28L 1 TOP246Y 1 PC817A 1 LMV431_A R4 R5 R6 R8 R10 R9 R27 R52 R28 R29 R30 R31 R32 R38 R47 R39 R48 R45 R46 R49 R51 R53 RT1 RV1 T1 U1 U2 U3
41W (53W pk) DVR
47 k, 5%, 1 W, Metal Oxide 240 R, 5%, 1/8 W, Carbon Film 10 R, 5%, 1/4 W, Carbon Film 6.8 R, 5%, 1/4 W, Carbon Film 6.81 k, 1%, 1/4 W, Metal Film 68 R, 5%, 1/4 W, Carbon Film 1 k, 5%, 1/4 W, Carbon Film 20 k, 5%, 1/8 W, Carbon Film 10 k, 1%, 1/4 W, Metal Film RSF100JB-47K CFR-12JB-240R CFR-25JB-10R CFR-25JB-6R8 MFR-25FBF-6K81 CFR-25JB-68R CFR-25JB-1K0 CFR-12JB-20K MFR-25FBF-10K0
March 7, 2005
Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo
30.9 k, 1%, 1/4 W, Metal Film 1 M, 5%, 1/4 W, Carbon Film 8.2 M, 5%, 1/4 W, Carbon Film 30 R, 5%, 1/2 W, Carbon Film 560 k, 5%, 1/4 W, Carbon Film 2 k, 1%, 1/4 W, Metal Film 100 R, 5%, 1/4 W, Carbon Film NTC Thermistor, 5 Ohms, 4.7 A 320 V, 26 J, 7 mm, RADIAL Bobbin, EER28L, Horizonal, 12 pins TOPSwitch-GX, TOP246Y, TO220-7C Opto coupler, 35 V, CTR 80-160%, 4-DIP 1.24V Shunt Reg IC
MFR-25FBF-30K9 CFR-25JB-1M0 CFR-25JB-8M2 CFR-50JB-30R CFR-25JB-560K MFR-25FBF-2K00 CFR-25JB-100R CL150 V320LA7 YW-195-00B TOP246Y ISP817A, PC817X1 LMV431ACZ
Yageo Yageo Yageo Yageo Yageo Yageo Yageo Thermometrics Littlefuse Yih-Hwa Enterprises Power Integrations Isocom, Sharp National Semiconductor
59 60 61
1 1N5250B 1 P6KE200A 1 1N5234B
VR4 VR5 VR10
20 V, 5%, 500 mW, DO-35 200 V, 5 W, 5%, DO204AC (DO-15) 6.2 V, 5%, 500 mW, DO-35
1N5250B P6KE200A 1N5234B
Microsemi Vishay Microsemi
NOTE: Large capacitors were used for the 12V output in order to prevent possible voltage overshoots from the reverse current coming from the Hard Disk Drive motor. Testing with the actual unit may show that these capacitors can be reduced for cost reduction.
Page 10 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
8 Transformer Specification
8.1 Electrical Diagram
1 WD#1 Cancellation 11T #29 x 4 NC WD#2 First Half Primary 3 22T #29 x 2 2 WD#3 Shield 1T CU Foil 1 WD#9 Bias 5 7T #29 6 WD#10 Second Half Primary 1 22T #29 x 2 3 7 WD#4 2T CU Foil 9 3.3V O/P 6T # 29 10 4T # 26 x 2 8 WD#5 1T CU Foil 5V O/P 11 WD#7 23V O/P 4T # 29 12 WD#8 30V O/P
WD#6 12V O/P
Figure 4 -Transformer Electrical Diagram
8.2
Electrical Specifications
1 second, 60 Hz, from Pins 1 - 6 to Pins 7 -12 Pins 1-2, all other windings open, measured at 132 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with Pins 7-12 shorted, measured at 132 kHz, 0.4 VRMS 3000 VAC 298 uH, -10/+10% 500 kHz (Min.) 6 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
Page 11 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44 8.3 Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10]
41W (53W pk) DVR
March 7, 2005
Description
Core: PC40 EER28L Bobbin: BEER28L Horizontal Magnet Wire: #29 AWG Magnet Wire: #26 AWG WD#3, CU Foil: see paragraph 8.4.1 for specification WD#4&5 CU Foil: see paragraph 8.4.2 for specification Tape: Margin 3 mm Tape: 3M 1298 Polyester Film, 15.8mm wide Tape: 3M 1298 Polyester Film, 22mm wide Teflon Tube
8.4
Transformer Build Diagram
1 3 6 5
WD#10 Second Half Primary WD#9 Bias Margin Tape
11 12 10 11 8 10 8 7 9
WD#8 30V O/P
WD#6 & WD7 12V &23V O/P WD#4 & WD#5 3.3V & 5V O/P
1 3 2
WD#3 Shield WD#2 First Half Primary WD#1 Cancellation
1
Figure 5 - Transformer Build Diagram.
Page 12 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
8.4.1 WD#3 Copper Foil build diagram:
Cu Foil 2mil; 16mm W x 49mm L 1-layer tape folded
47mm 29 AWG
Figure 6 - Copper Foil Build Diagram.
8.4.2 WDG#4 & #5 Copper Foil build diagram:
Cu Foil 2mil; 15.5mm W x 153mm L 1-layer tape folded
52mm 26 AWG X 2 26 AWG X 2
97mm 26 AWG X 4 Start from this end, reverse wind
Figure 7 - Copper Foil Build Diagram
Page 13 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
8.5
Transformer Construction
Bobbin Preparation Teflon Tube Margin Tape WD#1 Cancellation Insulation WD#2 Fist Half Primary Insulation WD #3 Shield Insulation Margin Tape WD #4 & WD #5 Insulation WD #6
WD #7
WD #8 Insulation WD #9 Insulation WD #10 Insulation Finish
Pin1 side of the bobbin orients to the left hand side. The machine spins clock-wise looking from right to left. All winding terminations shall be applied with item [10] Wind item [7] at the each pin side of the bobbin to match the height of the first half primary windings. Start on Pin 1, wind 11 turns quad-filar of item [3] from left to right. Wind th with tight tension. Cut the wires after finishing 11 turns. Overall, total 11 turns winding should be well fit the entire length of the bobbin. 2 Layers of tape [8] for insulation Start on pin 2, wind 22 turns of item [3] from left to right. After finishing the 22th turns, All the wires should be well fit the entire length of the bobbin. Bring the lead back to the left side and finish it on Pin 3. 1 Layer of tape [8] for insulation. Start at Pin 1, wind 1 turns of item [5]. Clock-wise wind with tension. Apply a small piece tape to secure the end of the foil. 3 Layers of tape [9] for insulation. Wind item [7] at the each pin side of the bobbin to match the height of the secondary windings. Start at pin 9, anti-clock-wise wind 2 turns of item [6]. Wind with tight. Finish the middle termination to pin 7, then continue to wind the last turn and finish it on pin 8. Apply a piece of tape to secure the end of the foil 1 Layer of tape [8] for insulation. Start at pin 10, wind 4 turns bifilar of item [4] from right to left. Wind uniformly, in a single layer across entire bobbin evenly. Bring the wire back and finish on pin 8. In the same layer, start at pin 11, wind 6 turns of item [3] from right to left. Wind between the wire gaps of the previous winding, in a single layer across entire bobbin evenly. Bring the wire back and finish on pin 10. In the same layer, start at pin 12, wind 4 turns of item [3] from right to left. Wind uniformly, in a single layer across entire bobbin evenly. Bring the wire back and finish on pin 11. 3 Layers of tape [9] for insulation. Start on Pin 5, wind 7 turns item [3] from left to right. Wind with tight th tension and scattered across the entire bobbin evenly. After finishing 7 turn, bring the wire back and finish it on Pin 6. 2 Layer of tape [8] for insulation. Start on pin 3, wind 22 turns of item [3] from left to right. After finishing the th 22 turns, All the wires should be well fit the entire length of the bobbin. Bring the lead back to the left side and finish it on Pin 1. 3 Layers of tape [9] for insulation. Grind the core to get 298uH. Secure the core with tape.
Page 14 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
8.6
41W (53W pk) DVR
March 7, 2005
Transformer Spreadsheets
INFO INFO OUTPU OUTPU UNIT T T TOP_GX_FX_032204.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer Volts Volts Hertz Volts Watts Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Volts Bias Voltage
ACDC_TOPSwitchGX_032204 INPUT ; Rev.1.9; Copyright Power Integrations Inc. 2004
ENTER APPLICATION VARIABLES
VACMIN VACMAX fL VO PO n Z VB tC 85 265 50 5 53 0.7 0.5 15 3
mSecon Bridge Rectifier Conduction Time Estimate ds
CIN
150
uFarads Input Filter Capacitor
ENTER TOPSWITCH-GX VARIABLES
TOP-GX
TOP246
TOP246 TOP246 Power Out Power Out
Univers 115 Doubled/230V al
Chosen Device
90W
125W
KI
1
External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT)
ILIMITMIN ILIMITMAX Frequency (F)=132kHz, (H)=66kHz fS F
2.511 2.889
2.511 Amps 2.889 Amps
Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Full (F) frequency option - 132kHz
132000 132000 Hertz
TOPSwitch-GX Switching Frequency: Choose between 132 kHz and 66 kHz
fSmin fSmax VOR VDS VD VDB KP 80 13 0.5 0.7 0.47
124000 124000 Hertz 140000 140000 Hertz Volts Volts Volts Volts
TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX Maximum Switching Frequency 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 (0.4 < KRP < 1.0 : 1.0< KDP<6.0)
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type Core Bobbin
eer28
EER28 EER28_ BOBBIN EER28 EER28_BOBBIN P/N: P/N: PC40EER28-Z BEER-28-1112CPH
AE LE AL BW M 3
0.821 6.4 2870 16.7
0.821 cm^2 6.4 cm 2870 nH/T^2 16.7 mm mm
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)
L NS
2 3
Number of Primary Layers Number of Secondary Turns
Page 15 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
DC INPUT VOLTAGE PARAMETERS
VMIN VMAX 86 375 86 Volts 375 Volts Minimum DC Input Voltage Maximum DC Input Voltage
CURRENT WAVEFORM SHAPE PARAMETERS
DMAX IAVG IP IR IRMS 0.52 0.88 2.20 1.03 1.24 0.52 0.88 Amps 2.20 Amps 1.03 Amps 1.24 Amps Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP 298 298 uHenrie Primary Inductance s NP NB ALG BM BP BAC ur LG BWE OD INS DIA AWG CM CMA 44 9 156 1830 2401 430 1780 0.62 21.4 0.49 0.07 0.43 26 256 207 44 9 156 nH/T^2 1830 Gauss 2401 Gauss 430 Gauss 1780 0.62 mm 21.4 mm 0.49 mm 0.07 mm 0.43 mm 26 AWG 256 Cmils Primary Winding Number of Turns Bias Winding Number of Turns Gapped Core Effective Inductance Maximum Flux Density at PO, VMIN (BM<3000) Peak Flux Density (BP<4200) 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
207 Cmils/A Primary Winding Current Capacity (200 < CMA < 500) mp
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT)
Lumped parameters ISP ISRMS IO IRIPPLE 32.03 17.18 10.60 13.52 32.03 Amps 17.18 Amps 10.60 Amps 13.52 Amps Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current
CMS AWGS
3437 14
3437 Cmils 14 AWG
Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value)
DIAS ODS INSS
1.63 3.57 0.97
1.63 mm 3.57 mm 0.97 mm
Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness
VOLTAGE STRESS PARAMETERS
VDRAIN 563 563 Volts Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) PIVS PIVB 31 89 31 Volts 89 Volts Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
Page 16 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 0.5 2.07 2.432 1.91 21 2.07 2.432 Amps 1.91 Amps 21 Volts 3.3 1.500 4.95 Volts Amps 4.95 Watts Volts 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
CMS1 AWGS1 DIAS1 ODS1 2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 CMS2 AWGS2 DIAS2 ODS2 3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 0.7 22.0 0.100 0.5 12.0 0.700
486 23 0.58 5.16
486 Cmils 23 AWG 0.58 mm 5.16 mm
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
Volts Amps 8.40 8.40 Watts Volts 6.82 1.135 0.89 71 227 26 0.41 1.57 6.82 1.135 Amps 0.89 Amps 71 Volts 227 Cmils 26 AWG 0.41 mm 1.57 mm
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 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
Volts Amps 2.20 2.20 Watts Volts 12.38 0.162 0.13 128 12.38 0.162 Amps 0.13 Amps 128 Volts
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
CMS3 AWGS3 DIAS3 ODS3
32 34 0.16 0.86
32 Cmils 34 AWG 0.16 mm 0.86 mm
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
Page 17 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency.
9.1 Line and Load Regulation
The test was done at 85 Vac and 265 Vac input, E-loads were used for the test. Vac Input 3.3V
VO/P (V) IO/P (A) VO/P (V)
5V
IO/P (A)
12V
VO/P (V) IO/P (A)
23V
VO/P (V) IO/P (A)
30V
VO/P (V) IO/P (A)
85V
265V
3.325 3.31 3.39 3.18 3.15 3.26 3.26 3.25 3.26 3.29 3.238 3.3 3.36 3.19 3.17 3.26 3.26 3.25 3.24 3.29
1.5 1 0.5 1.5 1.5 1.5 1.5 1.5 1.5 0.375 1.5 1 0.5 1.5 1.5 1.5 1.5 1.5 1.5 0.375
5.01 5.01 5.01 5.02 5.03 5.01 5.01 5.01 5.01 5.06 5.01 5.01 5.01 5.02 5.03 5.01 5.01 5.01 5.01 5.06
2 2 2 1 0.5 2 2 2 2 0.5 2 2 2 1 0.5 2 2 2 2 0.5
12.62 12.64 12.62 12.3 12.12 12.87 13.02 12.7 12.7 12.35 12.35 12.47 12.46 12.22 12.09 12.67 12.89 12.48 12.47 12.35
2 2 2 2 2 1 0.5 2 2 0.5 2 2 2 2 2 1 0.5 2 2 0.5
23.5 23.57 23.54 22.97 22.63 23.69 23.65 23.94 23.68 22.8 22.80 23.26 23.22 22.76 22.49 23.24 23.29 23.94 23.23 22.78
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.25 0.5 0.125 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.25 0.5 0.125
31.0 31 30.9 30.2 29.7 31.16 31.1 31.29 33.8 30.5 30.5 30.6 30.6 30 29.7 30.7 31.8 31.29 31.5 30.4
0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 20 20 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 20 20
Page 18 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
9.2 Efficiency
41W (53W pk) DVR
March 7, 2005
Efficiency vs Load
0.9 0.8 Efficiency 0.7 0.6 0.5 0.4 0.3 0% 20% 40% 60% Load Percentage 80% 100% 120% 115V 230V
Figure 8 - Efficiency
9.3
Overvoltage Protection
Test Result:
Under the all line and load conditions, short out the regulation optocoupler LED to simulate a loop failure. The power supply goes into auto restart mode, until the fault is removed.
PASS
Comment:
Page 19 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
10 Thermal Performance
Test Condition: The power supply was set on the bench and the all the loads were at full load except 12V loading at 1A. The total output power was 41W.
Temperature (C) Item Ambient (C) TOP246Y (U1) 85Vac (C) 265Vac
25 80 78
Page 20 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
11 Control Loop Measurements
The power supply is loaded at full load 53W to show worst case.
11.1 110 VAC Maximum Continuous Load
Figure 9 - Gain-Phase Plot, 110 VAC, 53W Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 938 Hz Phase Margin = 78.4
11.2 230 VAC Maximum Continuous Load
Figure 10 - Gain-Phase Plot, 230 VAC, 53W Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 1.19 kHz, Phase Margin = 87.28
Page 21 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
12 Waveforms
Waveforms were taken at 25oC. All outputs are loaded at full load, total 53W.
12.1 Drain Voltage and Current, Normal Operation
Figure 11 - 85 VAC, Full Load. Lower: IDRAIN, 1 A / div Upper: VDRAIN, 200 V, 2 s / div
Figure 12 - 265 VAC, Full Load Lower: IDRAIN, 1 A / div Upper: VDRAIN, 200 V, 2 s / div
12.2 Output Voltage Start-up Profile
12V 5V
12V 5V
3.3V
3.3V
Figure 13 - Start-up Profile, 85 VAC 1V/div for 3.3V & 5V, 2V/div for 12V, 50 ms / div.
Figure 14 - Start-up Profile, 265 VAC 1V/div for 3.3V & 5V, 2V/div for 12V, 50 ms / div.
Page 22 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
30V
30V
23V
23V
Figure 15 - Start-up Profile, 85 VAC 5V/div for 23V & 30V, 50 ms / div.
Figure 16 - Start-up Profile, 265 VAC 5V/div for 23V & 30V, 50 ms / div.
12.3 Drain Voltage Start-up Profile
Figure 17 - 90 VAC Input. Lower: IDRAIN, 1 A / div Upper: VDRAIN, 200 V, 50ms / div.
Figure 18 - 265 VAC Input. Lower: IDRAIN, 1 A / div Upper: VDRAIN, 200 V, 50ms / div.
Page 23 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
13 Output Ripple Measurements
13.1.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 19 and Figure 20. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 19 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 20 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
Page 24 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
13.1.2 Measurement Results The power supply was at 41W resistor load. 25Deg.C ambient.
Figure 21 85 VAC, 3.3V. 5 ms, 20 mV / div
Figure 22 265 VAC, 3.3V. 5 ms, 10 mV / div
Figure 23 85 VAC, 5V. 5 ms, 20 mV / div
Figure 24 265 VAC, 5V. 5 ms, 10 mV / div
Page 25 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
Figure 25 85 VAC, 12V. 5 ms, 50 mV / div
Figure 26 265 VAC, 12V. 5 ms, 10 mV / div
Figure 27 85 VAC, 23V. 5 ms, 100 mV / div
Figure 28 265 VAC, 23V. 5 ms, 10 mV / div
Page 26 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
Figure 29 85 VAC, 30V. 5 ms, 100 mV / div
Figure 30 265 VAC, 30V. 5 ms, 10 mV / div
Page 27 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
14 Conducted EMI
EMI was tested at room temperature and 230 VAC input. The power supply was at 41W resistor load. Two conditions were tested. (1) Secondary return connected to LISN ground (worst case), and (2) with no connection. Blue line is QP, Red line is AVG.
14.1 230V High Line EMI
Figure 31 - Line, Secondary Grounded
Figure 32 - Neutral, Secondary Grounded
Figure 33 - Line, Secondary Floating
Figure 34 - Neutral, Secondary Floating
Page 28 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
15 Revision History
Date March 7, 2005 Author DZ Revision 1.0 Description & changes Initial release Reviewed AM / VC
Page 29 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-44
41W (53W pk) DVR
March 7, 2005
For the latest updates, visit our Web site: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES 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 circuits external to the products and transformer construction) 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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
Power Integrations Worldwide Sales Support Locations
WORLD HEADQUARTERS 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: usasales@powerint.com CHINA (SHANGHAI) Rm 807, Pacheer, Commercial Centre, 555 Nanjing West Road, Shanghai, 200041, China Phone: +86-21-6215-5548 Fax: +86-21-6215-2468 e-mail: chinasales@powerint.com CHINA (SHENZHEN) Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu, Shenzhen, Guangdong, 518031, China Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 GERMANY Rueckertstrasse 3, D-80336, Munich, Germany Phone: +49-895-527-3910 Fax: +49-895-527-3920 e-mail: eurosales@powerint.com JAPAN Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama, 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com KOREA 8th Floor, DongSung Bldg. 17-8 Yoido-dong, Youngdeungpo-gu, Seoul, 150-874, Korea Phone: +82-2-782-2840 Fax: +82-2-782-4427 e-mail: koreasales@powerint.com SINGAPORE 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.co m TAIWAN 17F-3, No. 510, Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com
INDIA (TECHNICAL SUPPORT) Innovatech 261/A, Ground Floor 7th Main, 17th Cross, Sadashivanagar Bangalore, India, 560080 Phone: +91-80-5113-8020 Fax: +91-80-5113-8023 e-mail: indiasales@powerint.com ITALY Via Vittorio Veneto 12, Bresso, Milano, 20091, Italy Phone: +39-028-928-6001 Fax: +39-028-928-6009 e-mail: eurosales@powerint.com
UK (EUROPE & AFRICA HEADQUARTERS) 1st Floor, St. James's House East Street Farnham, Surrey GU9 7TJ United Kingdom Phone: +44-1252-730-140 Fax: +44-1252-727-689 e-mail: eurosales@powerint.com
APPLICATIONS FAX World Wide +1-408-414-9760
ER or EPR template - Rev 3.6 - Single sided
Page 30 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com

▲Up To Search▲

Price & Availability of DER-44

	To Download DER-44 Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .