View EPR-000013_1237467.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

Title
Engineering Prototype Report (EP13) 43 W / 57 W pk, 5 Output TOPSwitch-GX (TOP246Y) Power Supply
185 - 265 VAC input, 3.3 V / 3 A, 5 V / 3.2 A, 12 V / 0.6 A (1.8 A pk), 18 V / 0.5 A, 30 V / 0.03 A output. (Details for 115 VAC conversion included)
Specification Target Applications Author Document Number Date Revision
Features
* * * * * * * * * * * *
Set top box with internal hard drive, or other multiple output applications Power Integrations Applications Department EPR-000013 08-May-2001 1.0
Compact Design (6.875" L X 2.56" W X 1.56" H) 43 W steady state output power at 50 C ambient, free convection High efficiency (75% minimum at 180 VAC input, maximum continuous load) Low no-load power consumption (< 0.7 W @ 180 VAC, < 0.8 W @ 265 VAC) Multiple section transformer for low cost automated production Excellent output voltage tracking and cross regulation Primary soft-start minimizes component stress during start-up Low conducted EMI due to frequency jittering: meets CISPR22B/EN55022B Line overvoltage shutdown provides extended line surge protection Hysteretic thermal shutdown allows automatic supply recovery after fault removal Low component count with single sided printed circuit board Surge immunity up to 4 kV (surge or 100 kHz ring wave)
Power Integrations, Inc. 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
Table Of Contents
Introduction .................................................................................................................4 Power Supply Specification ........................................................................................5 Schematic ...................................................................................................................6 Circuit Description.......................................................................................................7 PCB Layout...............................................................................................................10 Bill Of Materials.........................................................................................................11 Transformer Specification .........................................................................................13 7.1 Electrical Specifications.........................................................................................13 7.2 Materials................................................................................................................13 7.3 Winding Instructions ..............................................................................................14 7.4 Transformer Sources.............................................................................................14 8 Transformer Spreadsheets .......................................................................................15 8.1 230 VAC, 60 W Peak Load .....................................................................................15 8.2 230 VAC, 45 W Steady State Load.........................................................................18 9 Performance Data.....................................................................................................21 9.1 Efficiency...............................................................................................................21 9.2 No-load Input Power..............................................................................................21 9.3 Regulation .............................................................................................................22 9.3.1 Maximum load all outputs ..............................................................................22 9.3.2 Peak load all outputs......................................................................................22 9.3.3 3.3 V Min. load, 12 V peak, other outputs fully loaded ...................................23 9.3.4 12 V Min. load, other outputs at maximum load condition..............................23 9.3.5 12 V Peak load, 30 V min. load, other outputs at max. load...........................24 9.3.6 5 V and 3.3 V min load, all other outputs maximum .......................................24 10 Thermal Performance ...............................................................................................25 11 Waveforms................................................................................................................26 11.1 Drain Voltage and Current, Normal Operation...................................................26 11.2 Output Voltage Start-up Profile..........................................................................26 11.3 Drain Voltage and Current Start-up Profile ........................................................27 11.4 Load Transient Response (75% to 100% Load Step)........................................28 11.5 Output Ripple Measurements ............................................................................29 11.5.1 Ripple Measurement Technique ....................................................................29 11.5.2 Measurement Results at 180 VAC...................................................................30 11.5.3 Measurement Results at 230 VAC...................................................................31 12 Control Loop Measurements.....................................................................................32 12.1 180 VAC Maximum Load ....................................................................................32 12.2 230 VAC Maximum Load ....................................................................................33 12.3 265 VAC Maximum Load ....................................................................................34 13 Conducted EMI .........................................................................................................35 14 AC Surge and 100 kHz Ring Wave Immunity ...........................................................35 14.1 Common Mode Surge, 1.2/50 sec ...................................................................36 14.2 Differential Mode Surge, 1.2/50 sec ................................................................36 14.3 Common Mode, 100 kHz Ring Wave.................................................................37 14.4 Differential Mode, 100 kHz Ring Wave ..............................................................37
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
1 2 3 4 5 6 7
Page 2 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
15 Appendix A - EP13, 115 VAC Version ...................................................................... 38 15.1 115 VAC Option Power Supply Specification.................................................... 38 15.2 Schematic for EP13 115 VAC-only Version........................................................ 39 15.3 EP13 115 VAC Version Circuit Description ........................................................ 40 15.4 EP13 115 VAC Transformer Drawing ................................................................. 41 15.5 Electrical Specifications .................................................................................... 41 15.6 Materials ........................................................................................................... 42 15.7 Transformer Construction Diagram................................................................... 42 15.8 Winding Instructions.......................................................................................... 43 15.8.1 Shield Foil Assembly ..................................................................................... 44 Secondary Foil Assembly......................................................................................... 44 15.8.3 Design Notes................................................................................................. 44 15.9 EP13 115 VAC Transformer Spreadsheets ........................................................ 45 15.9.1 115 VAC, 60 W Peak Load ............................................................................. 45 15.9.2 115 VAC, 45 W Steady State Load................................................................. 48 15.10 List of Included Parts for 230 VAC-115 VAC Conversion ................................. 51 15.11 EP13 230 VAC-115 VAC Conversion Instructions ............................................ 51 15.11.1 Required Tools and Supplies..................................................................... 51 15.11.2 Conversion Instructions ............................................................................. 51 16 Appendix B Miscellaneous Custom Parts ................................................................ 52 16.1 Secondary Heat Sink ........................................................................................ 52 17 Revision History ....................................................................................................... 53
Page 3 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
1 Introduction
This document is an engineering report describing a 230 VAC input, 5-output flyback supply utilizing TOPSwitch(R)-GX (TOP246Y). The supply is rated for 43 W continuous output power, with 57 W of peak power capability for starting a disk drive. The design is optimized for high-end set-top box applications, but is easily adapted for other multiple output uses such as VCRs, DVD players, cable modems, and direct satellite receivers. The design kit includes a component kit and instructions for converting the supply to 115 VAC input operation. This document contains the power supply specification, schematic, and bill of materials, transformer documentation, printed circuit layout, and performance data.
1.56" 6.875" 2.56"
Figure 1 - EP13 Populated Circuit Board.
Figure 2 - EP13 230 VAC Input to 115 VAC Input Retrofit Kit.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 4 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Output Voltage 3 Output Ripple Voltage 3 Output Current 3 Output Voltage 4 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 Surge Surge Ambient Temperature TAMB 4 4 0 50 kV kV
o
Symbol VIN fLINE
Min 180 47
Typ 230 50/60
Max 265 64 0.75 3.46 33 3.00 5.25 50 3.20 12.84 120 1.8
*
Units VAC Hz W V mV A V mV A V mV A V mV A V mV A W W %
Comment
2 Wire - no P.E.
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 VOUT5 VRIPPLE5 IOUT5 POUT POUT_PEAK
3.14 1.0 4.75 1.00 11.16
3.30 3.00 5.00 3.20 12.0
5% 20 MHz Bandwidth 5%
20 MHz Bandwidth
7%
20 MHz Bandwidth
*
0.30 16.74 0.5 29.7 0.01
0.60 18.00 33 -
Peak, 10 s max, thermally limited
7%
19.26 180 0.5 36.3 200 0.03 43 57
20 MHz Bandwidth
10%
20 MHz Bandwidth
75
Measured at POUT (43 W), 25 oC
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II 1.2/50 s surge, IEC 1000-4-5, 12 series impedance, differential and common mode 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, Sea level
C
Page 5 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
3 Schematic
Figure 3 - EP13 Schematic.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 6 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
4 Circuit Description
The EP13 is a five-output flyback power supply using the TOP246Y integrated circuit. The circuit shown in Figure 3 provides 43 W continuous power, with peak capability of 57 W (thermally limited). Input voltage range is 180-265 VAC. AC input power is rectified and filtered by D1-4 and C2 to provide a high voltage DC bus, which is applied to the primary of transformer T1. The TOP246Y DRAIN pin drives the other side of the transformer primary. Components D5, VR1, R2 and C5 clamp the DRAIN voltage leakage inductance spike to below the 700 V maximum rating of the TOPSwitch. The TOPSwitch-GX family provides several new features, as well as extended specifications. The EP13 power supply is designed to take advantage of several of these features. Resistor R1 connected to the LINE SENSE pin (L) of TOPSwitch-GX U1 is used to implement the built-in line voltage feed forward and overvoltage protection features. The line feed forward feature modulates the control circuit of the TOPSwitch-GX with the AC line frequency ripple component of the input DC, reducing the line frequency ripple at the output of the supply. This simplifies the design of the power supply control loop by reducing the amount of control loop gain required at the line ripple frequency in order to meet output ripple specifications. The overvoltage feature shuts down the power supply if the rectified DC bus voltage exceeds approximately 450 V, set by the value of R1. The supply resumes operation when the bus voltage falls again below the overvoltage threshold value. This feature allows the supply to withstand severe line transients or extended surge conditions without damage. This is an attractive feature for products designed for markets with poor power quality. Resistor R4 connects to the EXTERNAL CURRENT LIMIT pin (X) of U1 and is used to externally program the device current limit to just above the peak primary current of the supply at maximum peak load, minimum line voltage. This allows the transformer to be better optimized for the chosen operating conditions, while at the same time avoiding transformer core saturation during start-up or overload conditions. Transformer optimization choices can include using a smaller core (less expensive transformer), fewer primary turns (less leakage inductance), or higher primary inductance (more continuous operation, less TOPSwitch dissipation). The EP13 transformer design does not take full advantage of the flexibility offered by the TOPSwitch-GX due to secondary volts per turn required to minimize voltage error between 3.3 V and 5 V outputs. The secondary turns were deliberately chosen to optimize output voltage centering with the fewest possible number of turns. The reflected
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 7 of 56
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
voltage at the primary was fixed at 100 V to optimize output cross regulation, thus fixing the number of primary turns. A design with fewer output voltages can take better advantage of the design flexibility offered by the TOPSwitch-GX family. D6 and C3 provide a DC voltage of approximately 12 V to power the TOP246Y. A relatively large value of C3 (1 F) is used to provide bias voltage ride-through during severe output load transients. Capacitor C4 filters the internal bias supply of the TOPSwitch-GX, providing the necessary peak currents to drive the gate of its internal high-voltage MOSFET. Capacitor C4 also determines the TOPSwitch-GX auto-restart frequency, and along with resistor R3, helps to compensate the power supply control loop. Transformer T1 utilizes a nine section slotted bobbin designed for an automated production environment. Primary and secondary windings are applied in alternate bobbin slots using ordinary magnet wire. The slots provide the necessary safety isolation and creepage distance between the primary and secondary windings without the need for additional insulation of any kind. The large number of winding slots provides sufficient interleaving of primary and secondary windings to reduce the leakage inductance to a tolerable value, while the open construction of the transformer reduces winding temperature rise, allowing use of relatively fine wire, further facilitating automatic winding. Diodes D7, 8, 9, 10 and 11, along with capacitors C7, 9, 11, 13, 14, 16 and 17 are used to rectify and filter the five output secondary windings of T1. Two techniques are used to properly center the output voltages of the supply and to improve cross regulation between outputs. An ultrafast rectifier is used for D10 (5 V output rectifier) instead of a Schottky rectifier. The extra voltage drop of the ultrafast rectifier centers the 5 V output at precisely 5 V. Also, the 12 V, 18 V and 30 V secondary windings are stacked on the cathode side of the 5 V output rectifier (DC stacking) rather than the anode side (AC stacking). This means that the current for these outputs passes through the 5 V output rectifier (D10) as well as their respective output rectifiers (D7, 8, and 9). This increases the dissipation in D10, but has two beneficial effects. First, the extra voltage drop imposed by D10 precisely centers the 12 V output. Also, since the current for the 12 V, 18 V and 30 V outputs passes through D10 and its connecting printed circuit traces, variations in the current from these outputs will modulate the voltage drop across D10 to a certain extent. This change is passed on to the 5 V output, causing the output control loop to change the duty cycle to compensate. This indirect feedback improves the cross regulation of these outputs. Inductors L2, 3, 4, 5 and 6 are used along with capacitors C8, 10, 12, 15 and 18 to provide high frequency filtering for the five outputs of the supply. These filters greatly reduce the switching frequency ripple and high frequency spike noise at the outputs of the supply.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 8 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
A voltage divider consisting of resistors R10, 11 and 13 monitors the voltage on the 5 V and 3.3 V outputs. The resistor values are weighted so that the voltage feedback loop is controlled mostly by the 5 V output, with some contribution from the 3.3 V output. Sharing the voltage regulation control between the two outputs in this manner improves the cross regulation for the 3.3 V output at the expense of a slight change in the regulation of the 5 V output. The voltage from R10, 11 and 13 is applied to the reference pin of shunt regulator U3. These resistor values and the reference voltage of U3 are used to set the output voltages of the supply. Resistor R7 is used to set the overall gain of the supply control loop, while R8 provides bias current for U3. R9 and C19 provide frequency compensation for U3 to help stabilize the power supply control loop. Capacitor C20 is used to provide open loop feedback through optocoupler U2 during start-up, which in conjunction with the built-in soft start-up feature of TOPSwitch-GX, completely controls the start-up drain current profile, preventing transformer saturation and output overshoot. Optocoupler U2 applies the feedback signal from U3 to the CONTROL pin of U1. Resistor R15 and capacitor C24 form a snubber across D10 that reduces the reverse recovery transient from this diode, improving EMI performance. Inductor L7 is a ferrite bead placed in series with the 12 V, 18 V and 30 V output windings of T1. This bead acts as a small saturable reactor to improve the centering and cross regulation of these outputs. R6 provides a small amount of pre-filtering for the 30 V output, and is used to help prevent peak charging of this output due to leakage spikes. C1, L1 and C6 provide common-mode and differential mode EMI filtering for the power supply. Fuse F1 protects against gross circuit faults. Varistor RV1 is used to clamp differential mode line transients. Thermistor RT1 reduces the initial current surge when AC power is first applied to the circuit.
Page 9 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
5 PCB Layout
Figure 4 - EP13 Printed Circuit Layout. (Approximately 1:1 Scale)
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 10 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
6 Bill Of Materials
EP13 Set Top Supply, 230 VAC Slot Wound XFMR 1/25/01 Bill Of Materials
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Qty 1 1 1 1 1 1 1 1 1 2 1 4 2 2 1 1 Reference C1 C2 C3 C4 C5 C6 C7 C8 C9 C10, 12 C11 C13, 14,16,17 C15, 18 C19, 23 C20 C24 Description 0.22 F 250 V, X2 68 F, 400 V 1 F, 50 V NHG 47 F 16 V NHG 1 nF, 1 kV 2.2 F, Y1 47 F, 50 V NHG 10 F, 50 V NHG 330 F, 25 V HFQ 100 F, 25 V NHG 390 F, 35 V HFQ 1000 F, 25 V HFQ 220 F,16 V NHG 0.1 F, 50 V 22 F, 50 V NHG 1 nF, 50 V P/N 306 20224 ECO-S2GP680AA ECA-1HHG010 ECA-1CHG470 ECK-D3A102KBN 440LD22 ECA-1HHGG470 ECA-1HHG100 ECA-1EFQ331 ECA-1EHG101 ECA-1VFQ391 ECA-1EFQ102 ECA-1CHG221 K104M15Z5UF5TH5 ECA-1HHG220 K102K15X7Rf5TL2 Manufacturer Philips Panasonic Panasonic Panasonic Panasonic Cera-Mite Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Beyerschlag /Centralab Panasonic Beyerschlag /Centralab
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
4 1 1 1 2 1 1 1 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1
D1-4 D5 D6 D7 D8, 9 D10 D11 F1 L1 L2-5 L6 L7 R1 R2 R3 R4 R6, 15 R7 R8 R9 R10 R11 R13 R14
1 A, 1000 V 1 A, 600 V, 200 nsec Diode, 75 V 1 A, 200 V, 50 nsec 3 A, 200 V, 50 nsec 20 A, 200 V, 35 nsec 10 A, 45 V Schottky Fuse, 250 VAC 3.15 A 20 mH, 0.8 A 3.3 uH, 33 uH, 190 mA Ferrite Bead 2 M, 1/2 W, 5% 68 k, 2 W, 5% Metal Oxide 6.8 , 1/4 W, 5% 9.09 k, 1 %, RN55 10 , 1/4 W, 5% 150 , 1/4 W, 5% 1 k, 1/4 W, 5% 3.3 k, 1/4 W, 5% 9.53 k, 1%, RN55 10 k, 1%, RN55 15 k, 1%, RN55 2.7 k, 1/2 W, 5%
1N4007 1N4937 1N4148 UF4003 UF5402 BYV32-200 MBR1045 372-1315 ELF-18N008A 622-LY-3R3M 78F330J 2643022401
General Semiconductor General Semiconductor General Semiconductor Philips General Semiconductor Wickman Panasonic Toko J.W. Miller Fair-Rite
Page 11 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
41 42 43 44 45 46 47 48 49 50 51 1 1 1 1 1 1 1 1 1 1 1 T1 U1 U2 U3 RV1 VR1 RT1 J1 J2 HS1 HS2 XFMR, Custom Slotted Bobbin TOP246Y Optocoupler, graded CTR Shunt Regulator, 1% Varistor, 275 VAC, 14 mm TVS, 200 V, 600 W Thermistor, 10 ohm 1.7 A 3 pin, 0.156 ctr* 14 pin, 0.156 ctr. Heat Sink, TO-220, 1.5" ht. Heat Sink
08-May-2001
Orega Power Integrations Liteon TI General Semiconductor Keystone Molex Molex Aavid Custom
LTV817A TL431ACLP P6KE200 KC012L 26-60-2030 26-60-2140 531102N02500
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 12 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
7 Transformer Specification
Figure 5 - EP13 Multiple Slot Transformer.
7.1
Electrical Specifications
1 minute, 60 Hz, from Pins 1-9 to Pins 10-18 Pins 1-5 with Pins 3-4 shorted together, all other windings open, 130 kHz measurement frequency Pins 1-5 with Pins 3-4 shorted together, all other windings open Pins 1-5 with Pins 3-4 shorted together, Pins 1018 shorted together, 130 kHz measurement frequency 3000 VAC 487 H +/-10% 2 MHz minimum 15 H maximum
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
7.2
Materials
Item [1] [2] [3] Description 2 Orega SMT18 Core/Bobbin Set, Gap core for AL of 180 nH/T Magnet Wire, Solderable Double Coated 0.25 mm/30 AWG Epoxy Glue
Page 13 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
7.3
Winding Instructions
Slot # Slot 1 - Slot 2 - Start Pin Start Pin 5 Start Pin 11 Start Pin 14 Start Pin 16 Start Pin 17 Start Pin 18 Start Pin 3 Start Pin 8 Start Pin 11 Start Pin 14 Start Pin 14 Start Pin 5 Start Pin 11 Start Pin 15 Start Pin 15 Start Pin 16 Start Pin 4 Start Pin 11 Start Pin 15 Start Pin 16 Start Pin 17 Start Pin 18 Start Pin 5 Turns 26t 1t 2t 4t 3t 6t 26t 7t 1t 2t 2t 26t 1t 2t 2t 4t 26t 1t 2t 4t 3t 6t 26t Wire size 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25mm 0.25mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm Finish Pin Finish Pin 3 Finish Pin 14 Finish Pin 12 Finish Pin 10 Finish Pin 16 Finish Pin 17 Finish Pin 1 Finish Pin 9 Finish Pin 14 Finish Pin 12 Finish Pin 12 Finish Pin 4 Finish Pin 15 Finish Pin 13 Finish Pin 13 Finish Pin 10 Finish Pin 1 Finish Pin 15 Finish Pin 13 Finish Pin 10 Finish Pin 16 Finish Pin 17 Finish Pin 4
Slot 3 - Slot 4 -
Slot 5 - Slot 6 -
Slot 7 - Slot 8 -
Slot 9 -
7.4 Transformer Sources For information on the vendors used to source the transformers used on this board, please visit the Power Integrations' Web site at the URL below and select "Engineering Prototype Boards" http://www.powerint.com/componentsuppliers.htm
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 14 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
8 Transformer Spreadsheets
8.1 230 VAC, 60 W Peak Load
INPUT INFO OUTPUT UNIT TOP_GX_040401.xls: TOPSwitch-GX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer 180 265 50 3.3 60 0.7 0.5 12 3 68 TOP246 TOP246 0.8 1.944 Amps 2.376 Amps f 130000 1.30E+05 Hertz 1.24E+05 Hertz 1.40E+05 Hertz 99 10 0.5 0.7 0.60 Volts Volts Volts Volts Volts mSeconds
Farads
ACDC_TOPGX_Rev1.1_040401 Copyright Power Integrations Inc. 2000
ENTER APPLICATION VARIABLES
VACMIN VACMAX fL VO PO n Z VB tC CIN
ENTER TOPSwitch-GX VARIABLES
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 Bias Voltage Bridge Rectifier Conduction Time Estimate Input Filter Capacitor 115 Doubled/230 V 150 W External ILIMIT reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Full (F) frequency option - 130 kHz
TOPSwitch-GX Switching Frequency: Choose between 130 kHz and 65 kHz TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX Maximum Switching Frequency
TOP-GX Chosen Device KI ILIMITMIN ILIMITMAX Frequency - (F)=130 kHz, (H)=65 kHz fS fSmin fSmax VOR VDS VD VDB KP
Universal Power Out 90 W
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 AE LE AL BW M L NS
EER28L EER28L EER28L_BOBBIN P/N: P/N: 7.55 cm 2520 nH/T^2 21.8 mm 0 3.3 2 mm 0.814 cm^2 PC40EER28L-Z BEER-28L-1112CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns
Page 15 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
DC INPUT VOLTAGE PARAMETERS
VMIN VMAX
CURRENT WAVEFORM SHAPE PARAMETERS
217 Volts 375 Volts 0.32 0.39 Amps 1.74 Amps 1.05 Amps 0.72 Amps 460 Henries 52 7 169 nH/T^2 1891 Gauss 2577 Gauss 567 Gauss 1860 0.56 mm 71.94 mm 1.38 mm 0.09 1.29 17 2048 Warning 2864
Minimum DC Input Voltage Maximum DC Input Voltage Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current Primary Inductance 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
DMAX IAVG IP IR IRMS
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP NP NB ALG BM BP BAC ur LG BWE OD INS DIA AWG CM CMA
Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film mm thickness) mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller AWG standard AWG value) Cmils Bare conductor effective area in circular mils !!!!!!!!!! DECREASE CMA> (decrease L (primary Cmils/Amp layers), increase NS, smaller Core)
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT)
Lumped parameters ISP ISRMS IO IRIPPLE CMS AWGS DIAS ODS INSS
VOLTAGE STRESS PARAMETERS
45.43 Amps 26.95 Amps 18.18 Amps 19.89 Amps 5390 Cmils 12 AWG 2.05 mm 10.90 mm 4.42 mm
Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
VDRAIN PIVS PIVB
603 Volts 18 Volts 60 Volts
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 16 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 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 CMS3 AWGS3 DIAS3 ODS3 1.4 10.21 0.741 Amps 0.55 Amps 91 Volts 148 Cmils 28 AWG 0.32 mm 2.14 mm 18.0 0.500 Volts Amps 9.00 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 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 1.4 7.05 0.889 Amps 0.66 Amps 63 Volts 178 Cmils 27 AWG 0.36 mm 3.09 mm 12.0 0.600 Volts Amps 7.20 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 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 0.7 3.00 4.743 Amps 3.50 Amps 27 Volts 949 Cmils 20 AWG 0.81 mm 7.27 mm 5.0 3.200 Volts Amps 16.00 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 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 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
8.2
230 VAC, 45 W Steady State Load
INPUT INFO OUTPUT UNIT TOP_GX_040401.xls: TOPSwitch-GX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer 180 265 50 3.3 45 0.75 0.5 12 3 68 TOP246 TOP246 0.8 1.944 Amps 2.376 Amps f 130000 1.30E+05 Hertz 1.24E+05 Hertz 1.40E+05 Hertz 99 10 0.5 0.7 0.79 Volts Volts Volts Volts Volts mSeconds
Farads
ACDC_TOPGX_Rev1.1_040401 Copyright Power Integrations Inc. 2000
ENTER APPLICATION VARIABLES
VACMIN VACMAX fL VO PO n Z VB tC CIN
ENTER TOPSwitch-GX VARIABLES
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 Bias Voltage Bridge Rectifier Conduction Time Estimate Input Filter Capacitor 115 Doubled/230 V 150 W External ILIMIT reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Full (F) frequency option - 130 kHz
TOPSwitch-GX Switching Frequency: Choose between 130 kHz and 65 kHz TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX Maximum Switching Frequency
TOP-GX Chosen Device KI ILIMITMIN ILIMITMAX Frequency - (F)=130 kHz, (H)=65 kHz fS fSmin fSmax VOR VDS VD VDB KP
Universal Power Out 90 W
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 AE LE AL BW M L NS
EER28L EER28L EER28L_BOBBIN P/N: P/N: 0.814 cm^2 7.55 cm 2520 nH/T^2 21.8 mm 0 1 2 229 Volts 375 Volts mm PC40EER28L-Z BEER-28L-1112CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Minimum DC Input Voltage Maximum DC Input Voltage
DC INPUT VOLTAGE PARAMETERS
VMIN VMAX
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 18 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
CURRENT WAVEFORM SHAPE PARAMETERS
DMAX IAVG IP IR IRMS
TRANSFORMER PRIMARY DESIGN PARAMETERS
0.31 0.26 Amps 1.39 Amps 1.10 Amps 0.50 Amps 458 Henries 52 7 169 nH/T^2 1501 Gauss 2565 Gauss 593 Gauss 1860 0.57 mm 21.8 mm
Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current Primary Inductance 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)
LP NP NB ALG BM BP BAC ur LG BWE
Effective Bobbin Width Maximum Primary Wire Diameter including OD 0.42 mm insulation Estimated Total Insulation Thickness (= 2 * film INS 0.06 mm thickness) DIA 0.36 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller AWG 28 AWG standard AWG value) CM 161 Cmils Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < CMA 321 Cmils/Amp 500) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP ISRMS IO IRIPPLE CMS AWGS DIAS ODS INSS
VOLTAGE STRESS PARAMETERS
36.24 Amps 19.45 Amps 13.64 Amps 13.86 Amps 3889 Cmils 14 AWG 1.63 mm 10.90 mm 4.64 mm
Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
VDRAIN PIVS PIVB
603 Volts 18 Volts 60 Volts
Page 19 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 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 CMS3 AWGS3 DIAS3 ODS3 1.4 10.21 0.713 Amps 0.51 Amps 91 Volts 143 Cmils 28 AWG 0.32 mm 2.14 mm 18.0 0.500 Volts Amps 9.00 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 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 1.4 7.05 0.856 Amps 0.61 Amps 63 Volts 171 Cmils 27 AWG 0.36 mm 3.09 mm 12.0 0.600 Volts Amps 7.20 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 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 0.7 3.00 4.563 Amps 3.25 Amps 27 Volts 913 Cmils 20 AWG 0.81 mm 7.27 mm 5.0 3.200 Volts Amps 16.00 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 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
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 20 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency
Efficiency vs. Vin
80% 79% 78% 77% Max Continuous Load Max Peak Load
Efficiency (%)
76% 75% 74% 73% 72% 71% 70% 160
180
200
220
240
260
280
AC Input Voltage
Figure 6 - Efficiency vs. Input Voltage, Full Load, Room Temperature, 60 Hz.
9.2
No-load Input Power
Zero Load Input Power vs. Line Voltage
0.8
0.75
Input Power (W)
0.7
0.65
0.6
0.55
0.5 160
180
200
220
240
260
280
AC Input Voltage (VAC)
Figure 7 - Zero Load Input Power vs. Input Line Voltage Room Temperature, 60 Hz.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 21 of 56
EPR-000013 - 43 W Multiple Output TOP246 Power Supply 9.3 Regulation
08-May-2001
9.3.1 Maximum load all outputs
Line Regulation, Full Load
105% 3.3V 5V 12V 18V 30V
Regulation (% of Absolute Voltage).
104%
103%
102%
101%
100%
99%
98% 160
180
200
220
240
260
280
AC Input Voltage (VAC)
Figure 8 - Line Regulation, Maximum Continuous Load
9.3.2 Peak load all outputs
Line Regulation - Peak Load
(3.3 V @ 3A, 5 V @ 3.2 A, 12 V @ 1.8 A, 18 V @ 0.5 A, 30 V @ 30 mA) 104% 3.3V 5V 12V 18V 30V
Regulation (% of Absolute Voltage)
103%
102%
101%
100%
99%
98% 160
180
200
220
240
260
280
AC Input Voltage
Figure 9 - Line Regulation, Peak Load Condition
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 22 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
9.3.3 3.3 V Min. load, 12 V peak, other outputs fully loaded
Line Regulation
(3.3 V @ 1 A, 5 V @ 3.2 A, 12 V @ 1.8 A, 18V @ 0.5 A, 30 V @ 30 mA)
105.0%
Regulation (% of Absolute Voltage).
103.0%
3.3V 5V 12V 18V 30V
101.0%
99.0%
97.0%
95.0% 160
180
200
220
240
260
280
AC Input Voltage (VAC)
Figure 10 - Line Regulation, 3.3 V @ 1 A, 12 V @ 1.8 A, All Other Outputs Maximum Steady State Load
9.3.4 12 V Min. load, other outputs at maximum load condition
Line Regulation - Peak Load Condition (3.3 V @ 3 A, 5 V @ 3.2 A, 12 V @ 0.3 A, 18 V @ 0.5 A, 30 V @ 30 mA)
106%
Regulation (% of Absolute Voltage).
105% 104% 103% 102% 101% 100% 99% 160
3.3V 5V 12V 18V 30V
180
200
220
240
260
280
AC Input Voltage
Figure 11 - Line Regulation, 12 V min, and all other outputs maximum load
Page 23 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply 9.3.5 12 V Peak load, 30 V min. load, other outputs at max. load
Line Regulation - Peak Load
(3.3 V @ 3 A, 5 V @ 3.2 A, 12 V @ 1.8 A, 18 V @ 0.6 A, 30 V @ 10 mA)
08-May-2001
110% Regulation (% of Absolute voltage).
108%
3.3V 5V 12V 18V 30V
106%
104%
102%
100%
98% 160
180
200
220
240
260
280
AC Input Voltage (VAC)
Figure 12 - Line Regulation - 12 V Peak, 30 V Min. Load Condition
9.3.6 5 V and 3.3 V min load, all other outputs maximum
Line Regulation
5V @ 1A, 3.3 V @ 1 A, 12 V @ 0.6 A, 18 V @ 0.5 A, 30 V @ 0.03 A
104%
Regualtion (% of Absolute Output Voltage).
103% 102% 101% 100% 99% 98% 97% 96% 95% 160
3.3V 5V 12V 18V 30V
180
200
220
240
260
280
AC Input Voltage
Figure 13 - Line Regulation - 5 V and 3.3 V minimum, other output maximum load
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 24 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
10 Thermal Performance
Item Ambient Balun (L1) Thermistor (RT1) Snubber Resistor (R2) Clamp Zener (VR1) TOPSwitch (U1) Transformer (T1) 18V Rectifier (D8) 12V Rectifier (D9) 5V Rectifier (D10) 3.3V Rectifier (D11) 180 VAC 30.2 C 41.1 C 78.9 C 69.4 C 65.9 C 58.6 C 71.2 C 67.8 C 74.2 C 80.3 C 73.7 C Temperature 230 VAC 180 VAC 31.1 C 50.9 C 37.8 C 59.7 C 71.3 C 99.3 C 69.3 C 86.4 C 63.4 C 85.0 C 59.3 C 81 C 72.6 C 94.8 C 68.8 C 87.3 C 75.1 C 94.0 C 81.8 C 102.7 C 75 C 96.1 C 230 VAC 52 C 55.7 C 90.1 C 85.6 C 81.2 C 79.7 C 93.7 C 87.5 C 93.8 C 102.5 C 96.0 C
Figure 14 - EP13 Thermal Performance
Figure 15 - Infrared Thermograph of EP13, 180 VAC Input, Maximum Continuous Load, 22 C Ambient. (Board was sprayed black to give an accurate emissivity figure)
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 25 of 56
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
11 Waveforms
11.1 Drain Voltage and Current, Normal Operation
Figure 16 - 180 VAC - Upper: IDRAIN, 0.5 A / div, Lower: VDRAIN, 200 V / div, 2 s / div
Figure 17 - 265 VAC, Full Load - Upper: IDRAIN, 0.5 A / div, Lower: VDRAIN, 200 V / div, 2 s / div
11.2 Output Voltage Start-up Profile
Figure 18 - Start-up Profile, 3.3 V, 5 V and 12 V outputs. 2 V & 5 ms / div.
Figure 19 - Start-up Profile, 5 V, 18 V and 30 V outputs. 2 V & 5 ms / div.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 26 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
11.3 Drain Voltage and Current Start-up Profile
Figure 20 - 180 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 100 V & 2 ms / div.
Figure 21 - 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 100 V & 2 ms / div.
Page 27 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
11.4 Load Transient Response (75% to 100% Load Step) In the figures shown below, signal averaging was used to better enable viewing the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response.
Figure 22 - 5 V and 3.3 V Transient Response. 75-100-75% Load Step 5 V output. Upper: 5 V, 100 mV / div. Middle: 3.3 V, 100 mV / div. Bottom: 5 V output current, 1 A / div. 500 s / div.
Figure 23 - 12, 18 and 30 V Transient Response. 75-100-75% Load Step 5 V output. Upper: 30 V, 200 mV / div. Middle1: 18 V, 200 mV / div. Middle2: 12 V, 200 mV / div. Bottom: 5 V output current, 1 A / div. 2 ms / div.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 28 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
11.5 Output Ripple Measurements 11.5.1 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 24 and Figure 25. 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 24 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 25 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
Page 29 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
11.5.2 Measurement Results at 180 VAC
Figure 26 - 3.3 V Ripple, 180 VAC, Full Load. 2 ms, 20 mV / div
Figure 29 - 18 V Ripple, 180 VAC, Full Load. 2 ms, 20 mV / div
Figure 27 - 5 V Ripple, 180 VAC, Full Load. 2 ms, 20 mV / div
Figure 30 - 33 V Ripple, 180 VAC, Full Load. 2 ms, 20 mV / div
Figure 28 - 12 V Ripple, 180 VAC, Full Load. 2ms, 20 mV / div
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 30 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
11.5.3 Measurement Results at 230 VAC
Figure 31 - 3.3 V Ripple, 230 VAC, Full Load. 2 ms, 20 mV / div
Figure 34 - 18 V Ripple, 230 VAC, Full Load. 2 ms, 20 mV / div
Figure 32 - 5 V Ripple, 230 VAC, Full Load. 2 ms, 20 mV / div
Figure 35 - 18 V Ripple, 230 VAC, Full Load. 2 ms, 20 mV / div
Figure 33 - 12 V Ripple, 230 VAC, Full Load. 2 ms, 20 mV / div
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 31 of 56
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
12 Control Loop Measurements
12.1 180 VAC Maximum Load
0 dB Gain
45 Phase Margin
Figure 36 - Gain-Phase Plot, 180 VAC, Maximum Steady State Load Vertical Scale: Gain = 10 dB/div, Phase = 30 /div.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 32 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
12.2 230 VAC Maximum Load
0 dB Gain
50 Phase Margin
Figure 37 - Gain-Phase Plot, 230 VAC, Maximum Steady State Load Vertical Scale: Gain = 10 dB/div, Phase = 30 /div.
Page 33 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
12.3 265 VAC Maximum Load
0 dB Gain
63 Phase Margin
Figure 38 - Gain-Phase Plot, 265 VAC, Maximum Steady State Load Vertical Scale: Gain = 10 dB/div, Phase = 30 /div.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 34 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
13 Conducted EMI
QP Limit Line
AV Limit Line
Quasi-peak scan
Average scan
Figure 39 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits.
14 AC Surge and 100 kHz Ring Wave Immunity
Four series of line transient tests were performed on the EP13 to determine the level of immunity attainable for the basic board. Testing was performed using a Keytek EMC Pro surge generator. The input voltage for the supply under test was 230 VAC, and the supply was loaded to the maximum continuous output power using resistive loads on each output. An LED was used to monitor the presence of output voltage and to detect output interruptions. Test for each series was terminated upon non-destructive interruption of output voltage, arcing, or non-recoverable interruption of output voltage. A test failure was defined as a non-recoverable interruption of output voltage requiring supply repair or recycling of input AC voltage.
Page 35 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
14.1 Common Mode Surge, 1.2/50 sec
Surge Voltage 1 kV 1 kV 1 kV 1.5 kV 1.5 kV 1.5 kV 2 kV 2 kV 2 kV 2.5 kV 2.5 kV 2.5 kV 3 kV 3 kV 3 kV 3.5 kV 3.5 kV 3.5 kV 4 kV 4 kV 4 kV Phase Angle () 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 Generator Impedance 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms Number of Strikes 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 1 Test Result PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS (board arcing, supply still operational)
14.2 Differential Mode Surge, 1.2/50 sec
Surge Voltage 1 kV 1 kV 1 kV 1.5 kV 1.5 kV 1.5 kV 2 kV 2 kV 2 kV 2.5 kV 2.5 kV 2.5 kV 3 kV 3 kV 3 kV 3.5 kV 3.5 kV 3.5 kV 4 kV 4 kV Phase Angle () 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 90 Generator Impedance 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms 12 ohms Number of Strikes 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 1 Test Result PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS (output interruption, board still functional)
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 36 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
14.3 Common Mode, 100 kHz Ring Wave
Surge Voltage (kV) 1 kV 1 kV 1 kV 2 kV 2 kV 2 kV 3 kV 3 kV 3 kV 4 kV 4 kV 4 kV 4.5 kV 4.5 kV 4.5 kV 5 kV 5 kV 5 kV 5.5 kV 5.5 kV 5.5 kV 6 kV * U1 failure Phase Angle () 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 Short Circuit Current 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A Number of Strikes 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 1 Test Result PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS FAIL*
14.4 Differential Mode, 100 kHz Ring Wave
Surge Voltage 3 kV 3 kV 3 kV 4 kV 4 kV 4 kV 4.5 kV 4.5 kV 4.5 kV 5 kV 5 kV 5 kV 5.5 kV 5.5 kV 5.5 kV 6 kV 6 kV 6 kV Phase Angle () 0 90 270 0 90 270 0 90 270 0 90 270 0 90 270 0 0 0 Short Circuit Current 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A Number of Strikes 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 Test Result PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS
Page 37 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
15 Appendix A - EP13, 115 VAC Version
A kit of parts is included in the DAK-13 to convert the EP13 supply from 230 V to 115 V operation. The EP13 printed circuit board is designed to accommodate these changes without modification, so that only a stuffing change is required. Specification, schematic, and modification information for the EP13 115 V version are shown below. 15.1 115 VAC Option Power Supply Specification
Description Input Voltage Output 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 Output Ripple Voltage 4 Output Current 4 Output Voltage 5 Output Ripple Voltage 5 Output Current 5 Symbol Min 85 3.14 1.0 4.75 1.00 11.16 0.30 16.74 0.5 27 0.01 Typ Max 132 3.46 33 3.00 5.25 50 3.20 12.84 120 1.8* 19.26 180 0.5 32.4 200 0.03 43 57 75% Units VAC V mV A V mV A V mV A V mV A V mV A W % @ maximum continuous load Meets CISPR22B/EN55022B Designed to meet IEC950, UL1950 Class II Free convection, sea level Comment 2 Wire +/-5% 20 MHz BW +/-5% 20 MHz BW +/-7% 20 MHz BW *Peak load, 10 sec max. +/-7% 20 MHz BW +/-10% 20 MHz BW
VOUT1 VRIPPLE1 IOUT VOUT2 VRIPPLE2 IOUT VOUT3 VRIPPLE3 IOUT VOUT4 VRIPPLE4 IOUT VOUT5 VRIPPLE5 IOUT
3.30 3.00 5.00 3.20 12.0 0.60 18.00 33 -
Total Output Power Continuous Output Power POUT_TOTAL Peak Output Power Efficiency Environmental Conducted EMI Safety Ambient Temperature
0 C
50 C
o
C
Table 1 - EP13 115 VAC Option Specification
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 38 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
15.2 Schematic for EP13 115 VAC-only Version
Figure 40 - Schematic for EP13 115 VAC only Version
Page 39 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
15.3 EP13 115 VAC Version Circuit Description The circuit shown in the schematic of Figure 38 is a 115 VAC-only version of the EP13. Several notable changes were made in the circuit to accommodate 115 VAC-only operation. C2 is changed from 68 F, 400 V to 150 F, 200 V. RT1, D1-4, and L1 were changed to devices with higher current rating to accommodate the increased current draw at 115 VAC. U1 is changed from a TOP246Y to a TOP247Y, which has a higher current rating. Since the 115 VAC-only supply runs at a higher primary peak and RMS current, the secondary RMS currents are correspondingly higher. To handle the increased secondary RMS ripple current, the filter capacitors in the 5 V and 3.3 V outputs (C13-14 and C1617) are changed to devices with a higher ripple current rating. R12 and C21 have been added on the secondary voltage control to inject AC ripple information from the 12 V output into the control circuit. This "ripple steering" circuit reduces the 12 V output ripple, especially at low AC input voltage. T1 is replaced with a conventional margin-wound ERL28 transformer, since the multiple section transformer used in the 230 VAC version of the EP13 cannot handle the higher primary and secondary currents present at lower input voltages. The 5 V and 3.3 V secondaries in this transformer are wound using copper foil to reduce resistive losses and improve cross regulation.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 40 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
15.4 EP13 115 VAC Transformer Drawing Set-Top GX ERL28 Transformer
14
WDG #6 6T
13
18 V
Shield
1
WDG#7 23t 25AWG
WDG #5 3T 2 X 27AWG
12
WDG #4 4T 2X 27 AWG
12 V
Primary 3
WDG #1 30t 25AWG
8 9
WDG #3B 1T CU FOIL
5V
4 6
11
WDG #3A 2T CU FOIL
3.3 V
Bias
WDG#2 7t 2 X 27 AWG
7
10
15.5 Electrical Specifications
Electrical strength Primary Inductance Resonant Frequency Primary leakage inductance 60 Hz 1 minute, from Pins 1-7 to Pins 8-14 Pins 1-4, All other windings open, 100 kHz Pins 1-4, All other windings open Pins 1-4, Pins 8-12 shorted, 100 kHz 3000 VAC 356 H 1.1 MHz <11 H
Page 41 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
15.6 Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] Description Core: ERL28, Nippon Ceramic NC-2H material or equivalent 2 Gap for AL of 128 nH/t Bobbin: ERL28 vertical, 14 pins, Jinbo Industrial JB-0039 or equivalent Magnet Wire: #25 AWG solderable double coated Magnet Wire: #27 AWG solderable double coated Copper foil 0.60" x .005" Copper foil 0.60" x .001" Tinned bus wire, 22 AWG Tape: 3M Type 1298 polyester film or equiv. 22.4 mm wide Tape: 3M Type 1298 polyester film or equiv. 16 mm wide Tape: 3M Type 44. polyester web or equiv. 3.2 mm wide (min) Transformer Varnish
15.7 Transformer Construction Diagram
Bobbin Pin Side 1 3 13 14 12 13 8
12
1/2 Primary
Tape T a
10 11 9 7 6
1
Secondaries
Bias Shield 1/2 Primary
3 4
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 42 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
15.8 Winding Instructions
Bobbin Preparation Margin Taping
st
1 Primary Winding Basic Insulation Shield
Basic Insulation Bifilar Bias Winding Reinforced Insulation Margin Taping Copper Foil Winding
Basic Insulation +12 V Bifilar Winding +18 V Bifilar Winding
+30V Winding
Reinforced Insulation Margin Taping 2 Primary Winding Outer Insulation Varnish
nd
Remove pins 2 and 5 on bobbin. Apply a 3.2 mm margin at each side of bobbin using item [10]. st Match combined height of 1 primary, shield and bias windings. Start at pin 4. Wind 30 turns of item [3] uniformly across the bobbin in one layer. Finish at pin 3. Apply one layer of tape [9] for basic insulation. Prepare shield assembly using items [4] and [6]. Position shield assembly so that termination wire is adjacent to pin 1. Wrap foil around bobbin, and insulate between overlapping foil ends using tape [9]. Terminate drain wire at pin 1. Apply one layer of tape [9] for basic insulation. Start at pin 6. Wind 7 bifilar turns of item [4] uniformly in a single layer, across entire width of bobbin. Finish on pin 7. Apply three layers of tape [8] for reinforced insulation. Apply a 3.2 mm margin at each side of bobbin using item [10]. Match combined height of secondary windings. Prepare cuffed foil assembly as shown below, using items [5], [7], [8], and [9]. Start foil winding at pin 9. Wind 1 turn and terminate tap at pin 11. Wind 2 additional turns and finish at pin 10. Apply one layer of tape [9] for basic insulation. Starting at pin12, wind 4 bifilar turns of item [4] evenly across bobbin. Finish at pin 8. Starting at pin 13, wind 3 bifilar turns of item [4] directly over the 12 V winding. Apply turns evenly across bobbin. Finish at Pin 12. Starting at pin 14, wind 6 turns of item [4] directly over the 18 V winding. Apply turns evenly across bobbin. Finish at Pin 13. Apply three layers of tape [8] for reinforced insulation. Apply a 3.2 mm margin at each side of bobbin using item [10]. Match height of 2nd primary winding. Start at pin 3. Wind 23 turns of item [3] uniformly across the bobbin in one layer. Finish at pin 1. Apply 3 Layers of tape [8] for outer insulation Impregnate transformer using item [11]
Page 43 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
15.8.1 Shield Foil Assembly 2.25" 1.1"
Copper Foil [6]
Shield Assembly
2" Termination Wire
Item [4]
15.8.2 Secondary Foil Assembly
6.1"
Tape [9] (2 places)
2" (3 places)
2.125"
Item [7] (3 places)
Tape [8] Copper Foil [5] Tap Finish
Start
Secondary Foil Assembly
15.8.3 Design Notes
Power Integrations Device Frequency of Operation Mode Peak Current Reflected Voltage (Secondary to Primary) Maximum DC Input Voltage Minimum DC Input Voltage TOP247 132 kHz Continuous 1.71 Amps 100 V 187 VDC 93 VDC
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 44 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
15.9 EP13 115 VAC Transformer Spreadsheets 15.9.1 115 VAC, 60 W Peak Load
ACDC_TOPGX_Rev1.1_040401 Copyright Power Integrations INPUT Inc. 2000
ENTER APPLICATION VARIABLES
INFO
OUTPUT UNIT
TOP_GX_040401.xls: TOPSwitch-GX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer
VACMIN VACMAX fL VO PO n Z VB tC CIN
ENTER TOPSwitch-GX VARIABLES
85 132 50 3.3 60 0.7 0.5 12 3 150 TOP247 TOP247 0.8 Power Out
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
Farads
Bias Voltage Input Filter Capacitor 115 Doubled/230 V 200 W External ILIMIT reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Full (F) frequency option - 130 kHz
mSeconds Bridge Rectifier Conduction Time Estimate
TOP-GX Chosen Device KI ILIMITMIN ILIMITMAX Frequency - (F)=130 kHz, (H)=65 kHz fS fSmin fSmax VOR VDS VD VDB KP
Universal 105 W
2.592 Amps 3.168 Amps f 130000 1.30E+05 Hertz 1.24E+05 Hertz 1.40E+05 Hertz 100 10 0.5 0.7 0.40 Volts Volts Volts Volts
TOPSwitch-GX Switching Frequency: Choose between 130 kHz and 65 kHz 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 AE LE AL BW M L NS
EER28L EER28L EER28L_BOBBIN P/N: P/N: 0.814 cm^2 7.55 cm 2520 nH/T^2 21.8 mm 3.2 2 2 mm PC40EER28L-Z BEER-28L-1112CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns
DC INPUT VOLTAGE PARAMETERS
Page 45 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
VMIN VMAX
CURRENT WAVEFORM SHAPE PARAMETERS
08-May-2001
80 Volts 187 Volts 0.59 1.07 Amps 2.27 Amps 0.91 Amps 1.41 Amps 356 Henries 53 7 128 nH/T^2 1886 Gauss 2630 Gauss 377 Gauss 1860 0.76 mm 30.8 mm 0.59 mm
Minimum DC Input Voltage Maximum DC Input Voltage Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current Primary Inductance 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
DMAX IAVG IP IR IRMS
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP NP NB ALG BM BP BAC ur LG BWE OD
Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film INS 0.07 mm thickness) DIA 0.52 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller AWG 24 AWG standard AWG value) CM 406 Cmils Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < CMA 289 Cmils/Amp 500) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP ISRMS IO IRIPPLE CMS AWGS DIAS ODS INSS
VOLTAGE STRESS PARAMETERS
59.79 Amps 31.05 Amps 18.18 Amps 25.17 Amps 6211 Cmils 12 AWG 2.05 mm 7.70 mm 2.82 mm
Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
VDRAIN PIVS PIVB 1st output VO1 IO1 PO1 VD1 0.7
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
417 Volts 10 Volts 36 Volts
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
5.0 3.200
Volts Amps 16.00 Watts Volts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop
Page 46 of 56
08-May-2001
NS1 ISRMS1 IRIPPLE1 PIVS1 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 CMS3 AWGS3 DIAS3 ODS3 1.4 18.0 0.500 1.4 12.0 0.600
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
3.00 5.465 Amps 4.43 Amps 16 Volts 1093 Cmils 19 AWG 0.91 mm 5.13 mm Volts Amps 7.20 Watts Volts 7.05 1.025 Amps 0.83 Amps 37 Volts 205 Cmils 26 AWG 0.41 mm 2.18 mm Volts Amps 9.00 Watts Volts 10.21 0.854 Amps 0.69 Amps 54 Volts 171 Cmils 27 AWG 0.36 mm 1.51 mm 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 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 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
Page 47 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
15.9.2 115 VAC, 45 W Steady State Load
ACDC_TOPGX_Rev1.1_04040 1 Copyright Power Integrations Inc. 2000 INPUT INFO OUTPUT UNIT TOP_GX_040401.xls: TOPSwitch-GX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer 85 132 50 3.3 45 0.7 0.5 12 3 150 TOP247 TOP247 0.8 2.592 Amps 3.168 Amps f 130000 1.30E+05 Hertz 1.24E+05 Hertz 1.40E+05 Hertz 100 10 0.5 0.7 0.55 Volts Volts Volts Volts Power Out Volts
Farads
ENTER APPLICATION VARIABLES
VACMIN VACMAX fL VO PO n Z VB tC CIN
ENTER TOPSwitch-GX VARIABLES
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 Bias Voltage Input Filter Capacitor 115 Doubled/230 V 200 W External ILIMIT reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Full (F) frequency option - 130 kHz
TOPSwitch-GX Switching Frequency: Choose between 130 kHz and 65 kHz TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX Maximum Switching Frequency
mSeconds Bridge Rectifier Conduction Time Estimate
TOP-GX Chosen Device KI ILIMITMIN ILIMITMAX Frequency - (F)=130 kHz, (H)=65 kHz fS fSmin fSmax VOR VDS VD VDB KP
Universal 105 W
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 AE LE AL BW M L NS
EER28L EER28L EER28L_BOBBIN P/N: P/N: 7.55 cm 2520 nH/T^2 21.8 mm 3.2 2 2 92 Volts 187 Volts mm 0.814 cm^2 PC40EER28L-Z BEER-28L-1112CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Minimum DC Input Voltage Maximum DC Input Voltage
DC INPUT VOLTAGE PARAMETERS
VMIN VMAX
CURRENT WAVEFORM SHAPE PARAMETERS Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 48 of 56
08-May-2001
DMAX IAVG IP IR IRMS
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
0.55 0.70 Amps 1.75 Amps 0.97 Amps 0.97 Amps 359 Henries 53 7 130 nH/T^2 1470 Gauss 2654 Gauss 404 Gauss 1860 0.75 mm 30.8 mm 0.59 mm Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current Primary Inductance 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
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP NP NB ALG BM BP BAC ur LG BWE OD
Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film INS 0.07 mm thickness) DIA 0.52 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller AWG 24 AWG standard AWG value) CM 406 Cmils Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < CMA 421 Cmils/Amp 500) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP ISRMS IO IRIPPLE CMS AWGS DIAS ODS INSS
VOLTAGE STRESS PARAMETERS
46.18 Amps 23.00 Amps 13.64 Amps 18.52 Amps 4600 Cmils 13 AWG 1.83 mm 7.70 mm 2.94 mm
Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
VDRAIN PIVS PIVB 1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 0.7 5.0 3.200
417 Volts 10 Volts 36 Volts
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
Volts Amps 16.00 Watts Volts 3.00 5.397 Amps
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 49 of 56
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
IRIPPLE1 PIVS1 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 CMS3 AWGS3 DIAS3 ODS3 1.4 16.53 0.051 Amps 0.04 Amps 89 Volts 10 Cmils 39 AWG 0.09 mm 0.93 mm 30.0 0.030 Volts Amps 0.90 Watts Volts Output Voltage Output DC Current Output Power 1.4 7.05 1.012 Amps 0.81 Amps 37 Volts 202 Cmils 27 AWG 0.36 mm 2.18 mm 12.0 0.600 Volts Amps 7.20 Watts Volts Output Voltage Output DC Current Output Power 4.35 Amps 16 Volts 1079 Cmils 19 AWG 0.91 mm 5.13 mm
08-May-2001
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
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
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
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 50 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
15.10 List of Included Parts for 230 VAC-115 VAC Conversion
Set-Top GX, 115 V, Conversion Kit Bill Of Materials Item Qty Reference Description 150 F, 200 VEB 1200 F, 35 V FA 0.1 F, 50 V 2 A, 600 v 18 mH, 1.3 A 18 k, 1/4 W, 5% Transformer, Custom, TOP247Y Thermistor, 10 , 3.2 A Zero ohm resistor
P/N
Manufacturer
1 2 3 4 5 6 7 8 9 10
1 4 2 4 1 1 1 1 1 1
C2 C13,14,16,17 C21,22 D1-4 L1 R12 T1 U1 RT1 JP5
EEU-EB2D151 EEU-FA1V122L K104M15Z5UF5TH5 RL205 ELF-20N013A ERL28 KC011L
Panasonic Panasonic Beyerschlag/Centralab Diodes, Inc. Panasonic
Keystone
15.11 EP13 230 VAC-115 VAC Conversion Instructions 15.11.1 Required Tools and Supplies 1) Soldering iron 2) Solder 3) Pliers 4) Desoldering tool/solder wick 5) Philips screwdriver 6) Thermal compound 15.11.2 Conversion Instructions 1) Remove C2, C13-17, D1-4, L1, T1, U1, and RT1. Retain mounting screw and nut from U1 heat sink for reuse. 2) Replace C2 with 150 F, 200 V capacitor from conversion kit. Observe proper polarity. 3) Replace C13, 14, 16, and 17 with 1200 F, 35 V capacitors from conversion kit. Observe proper polarity. 4) Replace D1-4 with RL205 diodes from conversion kit. Check for proper diode polarity according to PCB silkscreen. 5) Replace L1 with 18 mH common mode inductor from conversion kit. 6) Replace U1 with TOP247Y from conversion kit. Use thermal compound between device mounting tab and heat sink to assure proper thermal interface. 7) Replace T1 with transformer from conversion kit. 8) Replace RT1 with thermistor from conversion kit. 9) Populate C21 and C22 positions with 0.1 F capacitors from conversion kit. 10) Populate R12 position with 18 k resistor from conversion kit. 11) Populate JP5 position using zero ohm resistor from conversion kit.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 51 of 56
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
16 Appendix B Miscellaneous Custom Parts
16.1 Secondary Heat Sink
Figure 41 - EP13 Secondary Heat Sink Drawing.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 52 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
17 Revision History
Date 25-Jan-2001 12-Apr-2001 16-Apr-2001 08-May-2001 Author RH RH RH RH Revision 0.1 0.2 0.3 1.0 Description & changes First draft Second draft Third Draft First Release
Page 53 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
Notes
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 54 of 56
08-May-2001
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
Notes
Page 55 of 56
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000013 - 43 W Multiple Output TOP246 Power Supply
08-May-2001
For the latest updates, visit our website: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein, nor does it convey any license under its patent rights or the rights of others. PI Logo, TOPSwitch and TinySwitch are registered trademarks of Power Integrations, Inc. (c)Copyright 2001, Power Integrations, Inc.
WORLD HEADQUARTERS NORTH AMERICA - WEST Power Integrations, Inc. 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 CHINA Power Integrations International Holdings, Inc. Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu Shenzhen Guangdong, 518031 Phone: +86*755*367*5143 Fax: +86*755*377*9610 APPLICATIONS HOTLINE World Wide +1*408*414*9660
NORTH AMERICA - EAST & SOUTH AMERICA Power Integrations, Inc. Eastern Area Sales Office 1343 Canton Road, Suite C1 Marietta, GA 30066 USA Phone: +1*770*424*5152 Fax: +1*770*424*6567
EUROPE & AFRICA Power Integrations (Europe) Ltd. Centennial Court Easthampstead Road Bracknell Berkshire RG12 1YQ, United Kingdom Phone: +44*1344*462*301 Fax: +44*1344*311*732 JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222, Japan Phone: +81*45*471*1021 Fax: +81*45*471*3717
TAIWAN Power Integrations International Holdings, Inc. 2F, #508, Chung Hsiao E. Rd., Sec. 5, Taipei 105, Taiwan Phone: +886*2*2727*1221 Fax: +886*2*2727*1223
KOREA Power Integrations International Holdings, Inc. Rm# 402, Handuk Building, 649-4 Yeoksam-Dong, Kangnam-Gu, Seoul, Korea Phone: +82*2*568*7520 Fax: +82*2*568*7474 APPLICATIONS FAX World Wide +1*408*414*9760
INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore, India 560052 Phone: +91*80*226*6023 Fax: +91*80*228*9727
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 56 of 56

▲Up To Search▲

Price & Availability of EPR-000013

	To Download EPR-000013 Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .