View DER-98_4120902.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

power integrations 5245 hellyer avenue, san jose, ca 95138 usa. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com design example report title 41w (53wpk) power supply using top246y specification input: 85 ? 265 vac output: 30v/80ma, 23v/0.5a, 12v/2a, 5v/2a, 3.3v/1.5a application digital video recorder author power integrations applications department document number DER-98 date september 12, 2005 revision 1.0 summary and features ? no linear regulators used ? one transformer solution ? good cross regulation ? no heat sinks 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 .
DER-98 41w (53w pk) dvr september 12, 2005 page 2 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com table of contents 1 introduction ................................................................................................................... 4 2 photograph.................................................................................................................... 4 3 power supply specification........................................................................................... 5 4 schematic ..................................................................................................................... 6 5 circuit descr iption ......................................................................................................... 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 mate rials ............................................................................................................. 9 8 transformer specification ........................................................................................... 11 8.1 electrical diagram ................................................................................................ 11 8.2 electrical spec ifications ....................................................................................... 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 curren t, normal operation ..................................................... 22 12.2 output voltage start-up profile ............................................................................ 22 12.3 drain voltage star t-up profile............................................................................... 23 13 output ripple measurements .................................................................................. 24 13.1.1 ripple measur ement technique ................................................................... 24 13.1.2 measurement results ................................................................................... 25 14 conducted emi ........................................................................................................ 28 14.1 230v high line emi ............................................................................................. 28 15 revision history....................................................................................................... 29
DER-98 41w (53w pk) dvr september 12, 2005 page 3 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com important notes: 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 isolated source to provide power 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.
DER-98 41w (53w pk) dvr september 12, 2005 page 4 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 1 introduction this document is an engineering prototype 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-shield tm transformer winding techniques. this document contains the pow er supply specifications, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. 2 photograph figure 1 ? circuit board photograph
DER-98 41w (53w pk) dvr september 12, 2005 page 5 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 3 power supply specification description symbol min typ max units comment input voltage v in 90 265 vac 2 wires system frequency f line 47 50/60 64 hz output voltage 1 v out1 3.135 3.3 3.465 v +/- 5% output ripple voltage 1 v ripple1 mv 20 mhz bandwidth for all the outputs output current 1 i out1 1.5 a output voltage 2 v out2 4.75 5.0 5.25 v +/- 5% output ripple voltage 2 v ripple2 mv 20 mhz bandwidth for all the outputs output current 2 i out2 2 a output voltage 3 v out3 11.4 12 12.6 v +/- 5% output ripple voltage 3 v ripple3 mv 20 mhz bandwidth for all the outputs output current 3 i out3 2 a output voltage 4 (fl) v out4 21.85 23 24.15 v +/- 5% output ripple voltage 4 v ripple4 mv 20 mhz bandwidth for all the outputs output current 4 i out4 0.5 a output voltage 5 v out5 28.5 30 31.5 v +/- 5% output ripple voltage 5 v ripple5 mv 20 mhz bandwidth for all the outputs output current 5 i out5 0.08 a total output power continuous output power p out 41 w peak output power p out_peak 53 w actual load measurement efficiency 72.8 % measured at 230vac, p out (41w), 25 o c environmental conducted emi meets cispr22b / en55022b safety designed to meet iec950, ul1950 class ii ambient temperature t amb 25 o c free convection, sea level the power supply is designed to meet 53 w output power for a short period ? a few minutes. the output power is only thermally limited by the heat sink attached to the top246y. in the currently sized heat sink (80 x 35 x 3 mm), the continuous output power is 41w.
DER-98 41w (53w pk) dvr september 12, 2005 page 6 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 4 schematic figure 2 ? schematic note: c33, c34, c16, r51, r52, r53, q2 and vr10 are added to the pcb bottom side.
DER-98 41w (53w pk) dvr september 12, 2005 page 7 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 re quired by u1 during startup, sets the auto- restart frequency during fault conditions, and also acts to roll off the gain of u1 as a function of frequency. r8 adds a zero to t he 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 12 v 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 30 v output winding; upon ov on the 5 v, detected by vr10, q2 will be triggered on to short the 30 v winding. the ps will go into auto-restart mode until the ov fault is removed.
DER-98 41w (53w pk) dvr september 12, 2005 page 8 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 ad ded to the pcb and mounted on the bottom side of the pcb
DER-98 41w (53w pk) dvr september 12, 2005 page 9 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7 bill of materials item qua. value part ref. description mfg part number mfg 1 1 150 uf c1 150 uf, 400 v, electrolytic, low esr, 410 mohm, (16 x 60) kmx400vb151m16x60l l united chemi-con 2 3 22 uf c3 c8 c9 22 uf, 50 v, electrolytic, very low esr, 340 mohm, (5 x 11) kze50vb22rme11ll united chemi-con 3 2 100 uf c4 c7 100 uf, 10 v, electrolytic, gen. purpose, (5 x 11) kme10vb101m5x11ll united chemi-con 4 2 100 nf c5 c21 100 nf, 50 v, ceramic, x7r ecu-s1h104kbb panasonic 5 2 1 nf c6 c34 1 nf, 1 kv, disc ceramic ncd102k1kvy5f nic components corp 6 1 220 uf c10 220 uf, 35 v, electrolytic, very low esr, 56 mohm, (8 x 15) kze35vb221mh15ll united chemi-con 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 x 20) kze10vb122mj20ll 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 1 10 nf c16 10 nf, 50 v, film ecq-v1h103jl3 panasonic 12 2 2700 uf c22 c25 2700 uf, 25 v, electrolytic, very low esr, 16 mohm, (16 x 25) kze25vb272ml25ll united chemi-con 13 1 33 uf c23 33 uf, 35 v, electrolytic, very low esr, 300 mohm, (5 x 11) kze35vb33rme11ll united chemi-con 14 1 2.2 nf c31 2.2 nf, ceramic, y1 440ld22 vishay 15 1 330 nf c32 safety x capacitor, 270v any 16 1 100 pf c33 100 pf, 1 kv, disc ceramic ncd101k1kvy5f nic components corp 17 4 1n4007 d1 d2 d3 d4 1000 v, 1 a, rectifier, do-41 1n4007 vishay 18 1 1n4007gp d5 1000 v, 1 a, rectifier, glass passivated, 2 us, do-41 1n4007gp vishay 19 1 bav20 d6 200 v, 200 ma, fast switching, 50 ns, do-35 bav20 vishay 20 1 byv26b d8 400 v, 1 a, ultrafast recovery, 30 ns, sod57 byv26b philips 21 1 sb560 d9 60 v, 5 a, schottky, do-201ad sb560 vishay 22 1 sb540 d10 40 v, 5 a, schottky, do-201ad sb540 vishay 23 1 uf4004 d11 400 v, 1 a, ultrafast recovery, 50 ns, do-41 uf4004 vishay 24 1 sb5100 d12 100 v, 5 a, schottky, do-201ad1 sb5100 fairchild 25 2 1n4001 d13 d15 50 v, 1 a, rectifier, do-41 1n4001 vishay 26 1 1n5817 d14 20 v, 1 a, schottky, do-41 1n5817 vishay 27 1 2 a f1 2 a,250v, slow, tr5 3,721,200,041 wickman 28 1 1.560h x 0.080w x 2.675l hs1 heatsink, custom, vestel, l shaped 29 1 con3 j9 ac input receptacle and accessory plug, pcbm 161-r301sn13 kobiconn 30 1 con8 j10 8 position (1 x 8) header, 0.1 pitch, vertical 22-28-4080 molex 31 1 con4 j11 4 position (1 x 4) header, 0.1 pitch, vertical 22-28-4049 molex 32 1 6.2 mh l1 6.2 mh, 1 a, common mode choke any any 33 5 3.3 uh l2 l3 l4 l5 l6 3.3 uh, 2.66 a 822ly-3r3m 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
DER-98 41w (53w pk) dvr september 12, 2005 page 10 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 36 1 47 k r4 47 k, 5%, 1 w, metal oxide rsf100jb-47k yageo 37 1 240 r5 240 r, 5%, 1/8 w, carbon film cfr-12jb-240r yageo 38 1 10 r6 10 r, 5%, 1/4 w, carbon film cfr-25jb-10r yageo 39 2 6.8 r8 r10 6.8 r, 5%, 1/4 w, carbon film cfr-25jb-6r8 yageo 40 1 6.81 k r9 6.81 k, 1%, 1/4 w, metal film mfr-25fbf-6k81 yageo 41 2 68 r27 r52 68 r, 5%, 1/4 w, carbon film cfr-25jb-68r yageo 42 1 1 k r28 1 k, 5%, 1/4 w, carbon film cfr-25jb-1k0 yageo 43 1 20 k r29 20 k, 5%, 1/8 w, carbon film cfr-12jb-20k yageo 44 1 10 k r30 10 k, 1%, 1/4 w, metal film mfr-25fbf-10k0 yageo 45 1 dnp r31 46 1 30.9 k r32 30.9 k, 1%, 1/4 w, metal film mfr-25fbf-30k9 yageo 47 2 1 m r38 r47 1 m, 5%, 1/4 w, carbon film cfr-25jb-1m0 yageo 48 2 8.2 m r39 r48 8.2 m, 5%, 1/4 w, carbon film cfr-25jb-8m2 yageo 49 1 30 r45 30 r, 5%, 1/2 w, carbon film cfr-50jb-30r yageo 50 2 560 k r46 r49 560 k, 5%, 1/4 w, carbon film cfr-25jb-560k yageo 51 1 2 k r51 2 k, 1%, 1/4 w, metal film mfr-25fbf-2k00 yageo 52 1 100 r53 100 r, 5%, 1/4 w, carbon film cfr-25jb-100r yageo 53 1 5 rt1 ntc thermistor, 5 ohms, 4.7 a cl150 thermometrics 54 1 320 vac rv1 320 v, 26 j, 7 mm, radial v320la7 littlefuse 55 1 eer28l t1 bobbin, eer28l, horizonal, 12 pins yw-195-00b yih-hwa enterprises 56 1 top246y u1 topswitch-gx, top246y, to220-7c top246y power integrations 57 1 pc817a u2 opto coupler, 35 v, ctr 80-160%, 4-dip isp817a, pc817x1 isocom, sharp 58 1 lmv431_a u3 1.24v shunt reg ic lmv431acz national semiconductor 59 1 1n5250b vr4 20 v, 5%, 500 mw, do-35 1n5250b microsemi 60 1 p6ke200a vr5 200 v, 5 w, 5%, do204ac (do-15) p6ke200a vishay 61 1 1n5234b vr10 6.2 v, 5%, 500 mw, do-35 1n5234b microsemi note : large capacitors were used for the 12 v 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.
DER-98 41w (53w pk) dvr september 12, 2005 page 11 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8 transformer specification 8.1 electrical diagram 12v o/p 11t #29 x 4 3 2 nc 12 11 first half primary 22t #29 x 2 4t # 26 x 2 wd#2 wd#1 wd#3 1 1t cu foil wd#6 10 1t cu foil 1 shield cancellation 8 2t cu foil 7 23v o/p 5v o/p wd#5 3.3v o/p wd#4 9 30v o/p wd#8 wd#7 5 6 bias 7t #29 wd#9 1 3 second half primary 22t #29 x 2 wd#10 6t # 29 4t # 29 figure 4 ? transformer electrical diagram 8.2 electrical specifications electrical strength 1 second, 60 hz, from pins 1 - 6 to pins 7 -12 3000 vac primary inductance pins 1-2, all other windings open, measured at 132 khz, 0.4 vrms 298 uh, -10/+10% resonant frequency pins 1-2, all other windings open 500 khz (min.) primary leakage inductance pins 1-2, with pins 7-12 shorted, measured at 132 khz, 0.4 vrms 6 h (max.)
DER-98 41w (53w pk) dvr september 12, 2005 page 12 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.3 materials item description [1] core: pc40 eer28l [2] bobbin: beer28l horizontal [3] magnet wire: #29 awg [4] magnet wire: #26 awg [5] wd#3, cu foil: see paragraph 8.4.1 for specification [6] wd#4&5 cu foil: see paragraph 8.4.2 for specification [7] tape: margin 3 mm [8] tape: 3m 1298 polyester film, 15.8mm wide [9] tape: 3m 1298 polyester film, 22mm wide [10] teflon tube 8.4 transformer build diagram wd#2 first half primary wd#1 cancellation wd#3 shield wd#4 & wd#5 3.3v & 5v o/p 11 8 2 12 wd#6 & wd7 12v &23v o/p wd#8 30v o/p 11 10 1 0 wd#9 bias 1 8 7 9 3 1 6 5 3 1 wd#10 second half primary margin tape figure 5 ? transformer build diagram
DER-98 41w (53w pk) dvr september 12, 2005 page 13 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.4.1 wd#3 copper foil build diagram: figure 6 ? copper foil build diagram 8.4.2 wdg#4 & #5 copper foil build diagram: figure 7 ? copper foil build diagram 29 awg 1-layer tape folded cu foil 2mil; 16mm w x 49mm l 47mm 1-layer tape folded cu foil 2mil; 15.5mm w x 153mm l 26 awg x 2 52mm 97mm 26 awg x 2 26 awg x 4 start from this end, reverse wind
DER-98 41w (53w pk) dvr september 12, 2005 page 14 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.5 transformer construction bobbin preparation pin1 side of the bobbin orients to the left hand side. the machine spins clock-wise looking from right to left. teflon tube all winding terminations shall be applied with item [10] margin tape wind item [7] at the each pin side of the bobbin to match the height of the first half primary windings. wd#1 cancellation start on pin 1, wind 11 turns quad-filar of item [3] from left to right. wind with tight tension. cut the wires after finishing 11 th turns. overall, total 11 turns winding should be well fit the entire length of the bobbin. insulation 2 layers of tape [8] for insulation wd#2 fist half primary start on pin 2, wind 22 turns of item [3] from left to right. after finishing the 22 th 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. insulation 1 layer of tape [8] for insulation. wd #3 shield 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. insulation 3 layers of tape [9] for insulation. margin tape wind item [7] at the each pin side of the bobbin to match the height of the secondary windings. wd #4 & wd #5 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 insulation 1 layer of tape [8] for insulation. wd #6 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. wd #7 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. wd #8 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. insulation 3 layers of tape [9] for insulation. wd #9 start on pin 5, wind 7 turns item [3] from left to right. wind with tight tension and scattered across the entire bobbin evenly. after finishing 7 th turn, bring the wire back and finish it on pin 6. insulation 2 layer of tape [8] for insulation. wd #10 start on pin 3, wind 22 turns of item [3] from left to right. after finishing the 22 th 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. insulation 3 layers of tape [9] for insulation. finish grind the core to get 298uh. secure the core with tape.
DER-98 41w (53w pk) dvr september 12, 2005 page 15 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.6 transformer spreadsheets acdc_topswitchgx_032204 ; rev.1.9; copyright power integrations inc. 2004 input info info outpu t outpu t unit top_gx_fx_032204.xls: topswitch-gx/fx continuous/discontinuous flyback transformer design spreadsheet enter application variables customer vacmin 85 volts minimum ac input voltage vacmax 265 volts maximum ac input voltage fl 50 hertz ac mains frequency vo 5 volts output voltage po 53 watts output power n 0.7 efficiency estimate z 0.5 loss allocation factor vb 15 volts bias voltage tc 3 msecon ds bridge rectifier conduction time estimate cin 150 ufarads input filter capacitor enter topswitch-gx variables top-gx top246 univers al 115 doubled/230v chosen device top246 top246 power out power out 90w 125w ki 1 external ilimit reduction factor (ki=1.0 for default ilimit, ki <1.0 for lower ilimit) ilimitmin 2.511 2.511 amps use 1% resistor in setting external ilimit ilimitmax 2.889 2.889 amps use 1% resistor in setting external ilimit frequency (f)=132khz, (h)=66khz f full (f) frequency option - 132khz fs 132000 132000 hertz topswitch-gx switching frequency: choose between 132 khz and 66 khz fsmin 124000 124000 hertz topswitch-gx minimum switching frequency fsmax 140000 140000 hertz topswitch-gx maximum switching frequency vor 80 volts reflected output voltage vds 13 volts topswitch on-state drain to source voltage vd 0.5 volts output winding diode forward voltage drop vdb 0.7 volts bias winding diode forward voltage drop kp 0.47 ripple to peak current ratio (0.4 < krp < 1.0 : 1.0< kdp<6.0) enter transformer core/construction variables core type eer28 core eer28 eer28 p/n: pc40eer28-z bobbin eer28_ bobbin eer28_bobbin p/n: beer-28-1112cph ae 0.821 0.821 cm^2 core effective cross sectional area le 6.4 6.4 cm core effective path length al 2870 2870 nh/t^2 ungapped core effective inductance bw 16.7 16.7 mm bobbin physical winding width m 3 mm safety margin width (half the primary to secondary creepage distance) l 2 number of primary layers ns 3 number of secondary turns
DER-98 41w (53w pk) dvr september 12, 2005 page 16 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com dc input voltage parameters vmin 86 86 volts minimum dc input voltage vmax 375 375 volts maximum dc input voltage current waveform shape parameters dmax 0.52 0.52 maximum duty cycle iavg 0.88 0.88 amps average primary current ip 2.20 2.20 amps peak primary current ir 1.03 1.03 amps primary ripple current irms 1.24 1.24 amps primary rms current transformer primary design parameters lp 298 298 uhenrie s primary inductance np 44 44 primary winding number of turns nb 9 9 bias winding number of turns alg 156 156 nh/t^2 gapped core effective inductance bm 1830 1830 gauss maximum flux density at po, vmin (bm<3000) bp 2401 2401 gauss peak flux density (bp<4200) bac 430 430 gauss ac flux density for core loss curves (0.5 x peak to peak) ur 1780 1780 relative permeability of ungapped core lg 0.62 0.62 mm gap length (lg > 0.1 mm) bwe 21.4 21.4 mm effective bobbin width od 0.49 0.49 mm maximum primary wire diameter including insulation ins 0.07 0.07 mm estimated total insulation thickness (= 2 * film thickness) dia 0.43 0.43 mm bare conductor diameter awg 26 26 awg primary wire gauge (rounded to next smaller standard awg value) cm 256 256 cmils bare conductor effective area in circular mils cma 207 207 cmils/a mp primary winding current capacity (200 < cma < 500) transformer secondary design parameters (single output / single output equivalent) lumped parameters isp 32.03 32.03 amps peak secondary current isrms 17.18 17.18 amps secondary rms current io 10.60 10.60 amps power supply output current iripple 13.52 13.52 amps output capacitor rms ripple current cms 3437 3437 cmils secondary bare conductor minimum circular mils awgs 14 14 awg secondary wire gauge (rounded up to next larger standard awg value) dias 1.63 1.63 mm secondary minimum bare conductor diameter ods 3.57 3.57 mm secondary maximum outside diameter for triple insulated wire inss 0.97 0.97 mm maximum secondary insulation wall thickness voltage stress parameters vdrain 563 563 volts maximum drain voltage estimate (includes effect of leakage inductance) pivs 31 31 volts output rectifier maximum peak inverse voltage pivb 89 89 volts bias rectifier maximum peak inverse voltage
DER-98 41w (53w pk) dvr september 12, 2005 page 17 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com transformer secondary design parameters (multiple outputs) 1st output vo1 3.3 volts output voltage io1 1.500 amps output dc current po1 4.95 4.95 watts output power vd1 0.5 volts output diode forward voltage drop ns1 2.07 2.07 output winding number of turns isrms1 2.432 2.432 amps output winding rms current iripple1 1.91 1.91 amps output capacitor rms ripple current pivs1 21 21 volts output rectifier maximum peak inverse voltage cms1 486 486 cmils output winding bare conductor minimum circular mils awgs1 23 23 awg wire gauge (rounded up to next larger standard awg value) dias1 0.58 0.58 mm minimum bare conductor diameter ods1 5.16 5.16 mm maximum outside diameter for triple insulated wire 2nd output vo2 12.0 volts output voltage io2 0.700 amps output dc current po2 8.40 8.40 watts output power vd2 0.5 volts output diode forward voltage drop ns2 6.82 6.82 output winding number of turns isrms2 1.135 1.135 amps output winding rms current iripple2 0.89 0.89 amps output capacitor rms ripple current pivs2 71 71 volts output rectifier maximum peak inverse voltage cms2 227 227 cmils output winding bare conductor minimum circular mils awgs2 26 26 awg wire gauge (rounded up to next larger standard awg value) dias2 0.41 0.41 mm minimum bare conductor diameter ods2 1.57 1.57 mm maximum outside diameter for triple insulated wire 3rd output vo3 22.0 volts output voltage io3 0.100 amps output dc current po3 2.20 2.20 watts output power vd3 0.7 volts output diode forward voltage drop ns3 12.38 12.38 output winding number of turns isrms3 0.162 0.162 amps output winding rms current iripple3 0.13 0.13 amps output capacitor rms ripple current pivs3 128 128 volts output rectifier maximum peak inverse voltage cms3 32 32 cmils output winding bare conductor minimum circular mils awgs3 34 34 awg wire gauge (rounded up to next larger standard awg value) dias3 0.16 0.16 mm minimum bare conductor diameter ods3 0.86 0.86 mm maximum outside diameter for triple insulated wire
DER-98 41w (53w pk) dvr september 12, 2005 page 18 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 5v 12v 23v 30v v o/p (v) i o/p (a) v o/p (v) i o/p (a) v o/p (v) i o/p (a) v o/p (v) i o/p (a) v o/p (v) i o/p (a) 3.325 1.5 5.01 2 12.62 2 23.5 0.5 31.0 0.08 3.31 1 5.01 2 12.64 2 23.57 0.5 31 0.08 3.39 0.5 5.01 2 12.62 2 23.54 0.5 30.9 0.08 3.18 1.5 5.02 1 12.3 2 22.97 0.5 30.2 0.08 3.15 1.5 5.03 0.5 12.12 2 22.63 0.5 29.7 0.08 3.26 1.5 5.01 2 12.87 1 23.69 0.5 31.16 0.08 3.26 1.5 5.01 2 13.02 0.5 23.65 0.5 31.1 0.08 3.25 1.5 5.01 2 12.7 2 23.94 0.25 31.29 0.08 3.26 1.5 5.01 2 12.7 2 23.68 0.5 33.8 20 85v 3.29 0.375 5.06 0.5 12.35 0.5 22.8 0.125 30.5 20 3.238 1.5 5.01 2 12.35 2 22.80 0.5 30.5 0.08 3.3 1 5.01 2 12.47 2 23.26 0.5 30.6 0.08 3.36 0.5 5.01 2 12.46 2 23.22 0.5 30.6 0.08 3.19 1.5 5.02 1 12.22 2 22.76 0.5 30 0.08 3.17 1.5 5.03 0.5 12.09 2 22.49 0.5 29.7 0.08 3.26 1.5 5.01 2 12.67 1 23.24 0.5 30.7 0.08 3.26 1.5 5.01 2 12.89 0.5 23.29 0.5 31.8 0.08 3.25 1.5 5.01 2 12.48 2 23.94 0.25 31.29 0.08 3.24 1.5 5.01 2 12.47 2 23.23 0.5 31.5 20 265v 3.29 0.375 5.06 0.5 12.35 0.5 22.78 0.125 30.4 20
DER-98 41w (53w pk) dvr september 12, 2005 page 19 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.2 efficiency efficiency vs load 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0% 20% 40% 60% 80% 100% 120% load percentage efficiency 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. comment: pass
DER-98 41w (53w pk) dvr september 12, 2005 page 20 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 10 thermal performance test condition: the power supply was set on the bench and the all the loads were at full load except 12 v loading at 1 a. the total output power was 41 w. temperature ( c) 85 vac 265 vac item ( c) ambient ( c) 25 top246y (u1) 80 78
DER-98 41w (53w pk) dvr september 12, 2005 page 21 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11 control loop measurements the power supply is loaded at full load 53 w 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
DER-98 41w (53w pk) dvr september 12, 2005 page 22 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 12 waveforms waveforms were taken at 25 o c. all outputs are loaded at full load, total 53 w. 12.1 drain voltage and current, normal operation figure 11 ? 85 vac, full load. lower: i drain , 1 a / div upper: v drain , 200 v, 2 s / div figure 12 ? 265 vac, full load lower: i drain , 1 a / div upper: v drain , 200 v, 2 s / div 12.2 output voltage start-up profile figure 13 ? start-up profile, 85 vac 1 v / div for 3.3 v & 5 v, 2 v / div for 12 v, 50 ms / div. figure 14 ? start-up profile, 265 vac 1 v / div for 3.3 v & 5 v, 2 v / div for 12v, 50 ms / div. 12v 5v 12v 5v 3.3v 3.3v
DER-98 41w (53w pk) dvr september 12, 2005 page 23 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com figure 15 ? start-up profile, 85 vac 5 v / div for 23 v & 30 v, 50 ms / div. figure 16 ? start-up profile, 265 vac 5 v / div for 23 v & 30 v, 50 ms / div. 12.3 drain voltage start-up profile figure 17 ? 90 vac input. lower: i drain , 1 a / div upper: v drain , 200 v, 50 ms / div. figure 18 ? 265 vac input. lower: i drain , 1 a / div upper: v drain , 200 v, 50 ms / div. 30v 23v 30v 23v
DER-98 41w (53w pk) dvr september 12, 2005 page 24 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 pi ckup. 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). 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) probe ground probe tip
DER-98 41w (53w pk) dvr september 12, 2005 page 25 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 13.1.2 measurement results the power supply was at 41w resistor load. 25deg.c ambient. figure 21 ? 85 vac, 3.3 v, 5 ms, 20 mv / div figure 22 ? 265 vac, 3.3 v, 5 ms, 10 mv / div figure 23 ? 85 vac, 5 v, 5 ms, 20 mv / div figure 24 ? 265 vac, 5 v, 5 ms, 10 mv / div
DER-98 41w (53w pk) dvr september 12, 2005 page 26 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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
DER-98 41w (53w pk) dvr september 12, 2005 page 27 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com figure 29 ? 85 vac, 30v, 5 ms, 100 mv / div figure 30 ? 265 vac, 30v, 5 ms, 10 mv / div
DER-98 41w (53w pk) dvr september 12, 2005 page 28 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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
DER-98 41w (53w pk) dvr september 12, 2005 page 29 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15 revision history date author revision description reviewed september 12, 2005 dz 1.0 initial release jc / am / vc
DER-98 41w (53w pk) dvr september 12, 2005 page 30 of 30 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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. ? copyright 2004, power integrations. power integrations worldwid e 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 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 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 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 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 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 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 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 italy via vittorio veneto 12, bresso, milano, 20091, italy phone: +39-028-928-6001 fax: +39-028-928-6009 e-mail: eurosales@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 applications hotline world wide +1-408-414-9660 applications fax world wide +1-408-414-9760 er or epr template ? rev 3.6 ? single sided

▲Up To Search▲

Price & Availability of DER-98

	To Download DER-98 Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .