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(R) TOPSwitch-II USB Reference Design Board 85 to 265 VAC Input, 15W Output
Product Highlights
Low Cost Production Worthy Reference Design * Complete self-powered USB power supply * Supports 4 ports and hub controller * Single sided board * Fully assembled and tested * Easy to evaluate and modify * Extensive performance data * Over 69% efficiency Fully Protected by TOPSwitch-II * Primary safety current limit * Output short circuit protection * Thermal shutdown protects entire supply Designed for World Wide Operation * Designed for IEC/UL safety requirements * Meets VDE Class B EMI specifications
4.29 in. (109 mm)
RD6
(R)
2.13 in. (54 mm)
1.07 in. (27 mm)
PI-2167-012098
Figure 1. RD6 Overall Physical Dimensions.
Description
The RD6 reference design board is an example of a low cost production worthy design for a self-powered, 4-port USB hub. The design is a complete solution for powering hubs found in products such as monitors and printers. A total of 15 W of power is delivered through two outputs. The main output supplies 3 A at 5 V. This meets the USB specification of 500 mA for each port (4 port total) with additional power available for a 5 V hub controller. A second 3.3 V (100 mA) output provides power for low voltage hub controllers. The RD6 utilizes the TOP223Y member of the TOPSwitch-II family of Three-terminal Off-line PWM Switchers from Power Integrations. It is intended to help TOPSwitch users to develop their products quickly by providing a production ready design which needs little or no modification to meet system requirements.
PARAMETER Input Voltage Range Input Frequency Range Temperature Range Output Voltage (Io = 3.0 A)
(Io = 0.1 A)
LIMITS 85 to 265 VAC 47 to 440 Hz 0 to 70 C 5 V 4% 3.3 V 3% 15 W 30 W 0.7% 1.1% 69% (min) 5V 40 mV MAX 3.3V 25 mV MAX IEC 950 / UL1950 VDE B (VFG243 B) CISPR22
Output Power (continuous) Output Power (peak) Line Regulation (85-265 VAC) Load Regulation (0%-100%) Efficiency Output Ripple Voltage Safety EMI
Figure 2. Table of Key Electrical Parameters.
March 1998
RD6
C11 470 pF 1 7, 8 VR1 P6KE200 5, 6 L2 22 mH BR1 600 V C1 47 F 400 V C6 0.1 F 250 VAC
D
R12 15 L1 3.3 H 5V
D2 MBR1045
C2 560 F 35 V D3 1N4148
C10 560 F 35 V
C3 220 F 35 V
RTN R6 16 1/2 W 3.3 V R4 3 K C8 10 nF C9 220 F 35 V U3 TL431
D1 UF4005 2 4
R1 4.7 R2 47 U2 PC817A VR2 IN5228C 3.9 V
TOPSwitch-II
CONTROL
C4 0.1 F T1 3
C
J1 L N
F1 3.15 A
S
U1 TOP223Y
C5 47 F
R3 6.8
C7 1 nF 250 VAC Y1
R5 10 K
PI-2135-030998
Figure 3. Schematic Diagram of the 15 W RD6 Power Supply.
BR1
C1
D2
T1 DCVR1 D1 F1 J1 HS1 POWER INTEGRATIONS INC. RD6 REV. A S/N C5 R3 C7 D3 U2 U1 C4
C11
R12 L1
C3
C6
J2 C2
C10 VR2 R2 R1 U3 C8 R5
R6
R4
C9
COMPONENT SIDE SHOWN
PI-2137-122297
Figure 4. Component Legend of the RD6.
General Circuit Description
The RD6 is a low-cost flyback switching power supply using the TOP223Y integrated circuit. The circuit shown in Figure 3 details a 5 V, 15 W power supply that operates from 85 to 265 VAC input voltage, suitable for powering a USB hub with as many as 4 ports, and a 3.3 V, 100 mA auxiliary output for powering a hub controller. AC power is rectified and filtered by BR1 and C1 to create the high voltage DC bus applied to the primary winding of T1. The other side of the transformer primary is driven by the integrated high-voltage MOSFET within the TOP223. D1 and VR1 clamp the voltage spike caused by transformer leakage inductance to a safe value and reduce ringing. The power secondary winding is rectified and filtered by D2, C2, C10, L1, and C3 to create the 5 V output voltage. The 5 V output is directly sensed by optocoupler U2 and Zener diode VR2. The output voltage is determined by the Zener diode VR2 plus the voltage drops across the LED of the optocoupler U2 and resistor R1. Other output voltages are also possible by adjusting the transformer turns ratios and the value
2
B 3/98
+3.3V GND +5V
L2
RD6 Component Listing
Reference BR1 C1 C2, C10 C3, C9 C4 C5 C6 C7 Value 600 V, 2 A 47 F, 400 V 560 F, 35 V 220 F, 35 V 0.1 F, 50 V 47 F, 10 V 0.1 F, 250 VAC, X2 1.0 nF, 250 VAC, Y1* Part Number Manufacturer General Instrument Panasonic Panasonic Panasonic Murata Panasonic Roederstein Roederstein Murata Cera-Mite Murata Murata General Instrument Motorola National Semiconductor J. W. Miller Panasonic Philips Philips Philips Philips Philips Philips Philips Custom Power Integrations Sharp Motorola Motorola APD Wickman 2KBPC06M ECA-2GG470YE ECA-1VFQ561 ECE-1AVGE221 RPE121Z5U104M50V ECE-A1AG470 F1772-410-2000 WKP102MCPE.OK DE1110E102M ACT4K-KD 440LD10 10 nF, 50 V RPE110Z5U103M50V 470 pF, 50 V RPE110X7R471K50V 600 V, 1 A, UFR UF4005 45 V, 10 A Schottky MBR1045 75 V, Switching 1N4148 3.3 H, 5.5 A 6000-3R3M 22 H, 0.4 A ELF-18D290C 4.7 , 1/4 W 5043CX4R700J 47 , 1/4 W 5043CX47R00J 6.8 , 1/4 W 5043CX6R800J 3.16 K, 1/4 W, 1% 5043EM3K160F 10.0 K, 1/4 W, 1% 5043EM10K00F 16 , 1/2 W 5053CX16R00J 15 , 1/4 W 5043CX15R00J TRD6 TOP223Y Optocoupler, Controlled CTR PC817A Adj. Shunt Regulator TL431CLP 200 V Zener TVS P6KE200 3.9 V 2% Zener 1N5228C 3.15 A, 250 VAC 19372, 3.15A
C8 C11 D1 D2 D3 L1 L2 R1 R2 R3 R4 R5 R6 R12 T1** U1 U2 U3 VR1 VR2 F1
Figure 5. Parts List for the RD6 (* Two Series-Connected 2.2 nF, Y2 Capaciors such as Murata P/N DE7100F222MVA1-KC can replace C7) ** T1 is available from Premier Magnetics (714) 362-4211 as P/N TSD-1106, and from Coiltronics (561) 241-7876 as P/N CTX14-13598
of Zener diode VR2. The 3.3 V output is derived from the 5 V output using R6 and shunt regulator U3. C11 and R12 form a snubber circuit across D2 to reduce ringing. This improves conducted RFI performance of the supply at high frequency (15-20 MHz) and reduces leakage spikes, improving the reliability of D2. R2 provides bias current for Zener VR2 to improve regulation. The primary bias winding is rectified and filtered by D3 and C4 to create a bias voltage to power the TOP223Y. L2 and Y1-capacitor C7 attenuate common-mode emission currents caused by high-voltage switching waveforms on the DRAIN side of the primary winding and the primary to secondary capacitance. L2 and C6 attenuate differential-mode emission currents caused by the fundamental and harmonics of the primary current waveform. C5 filters internal MOSFET gate drive charge current spikes on the CONTROL pin, determines
the auto-restart frequency, and together with R1 and R3, compensates the 5 V control loop. R6 and shunt regulator U3 are used to derive a 3.3 V supply from the 5V output. R4 and R5, along with the 2.5 V internal band gap reference in U3, are used to set the output voltage. C8 provides compensation for the 3.3 V control loop. C9 provides additional filtering for the 3.3 V output. As a shunt regulator, U3 provides a constant load of approximately 100 mA on the 5 V output, regardless of whether a load is present on the 3.3 V output. This provides a substantial preload for the 5 V output, greatly improving regulation at light or zero load. The circuit performance data shown in Figures 6-21 were measured with AC voltage applied to the RD6. Load Regulation (Figure 6) - The change in the DC output voltage for a given change in output current is referred to as load regulation. Both the 5 V and 3.3 V outputs stay within
B 3/98
3
RD6 General Circuit Description (cont.)
1.1 % of nominal from 0% to 100% of rated load current. The TOPSwitch on-chip over-temperature protection circuit will safely shut down the power supply under persistent overload conditions. Line Regulation (Figure 7) - The change in the DC output voltage for a given change in the AC input voltage is called line regulation. The maximum change in output voltage vs line for both the 5 V and 3.3 V outputs is within 0.7%. Efficiency (Line Dependent) - Efficiency is the ratio of the output power to the input power. The curves in Figures 8 and 9 show how the efficiency changes with input voltage. Efficiency (Load Dependent) - The curves in Figures 10 and 11 show how the efficiency changes with output power for 115 VAC and 230 VAC inputs. Power Supply Turn On Sequence - The internal switched, high-voltage current source provides the initial bias current for TOPSwitch when power is first applied. The waveforms shown in Figure 12 illustrate the relationship between the high-voltage DC bus and the 12 V output voltage. Capacitor C1 charges to the peak of the AC input voltage before TOPSwitch turns on. The delay of 150 ms (typical) is caused by the time required to charge the auto-restart capacitor C5 to 5.8 V. At this point the power supply turns on as shown. Figure 13 shows the 5 V output turn on transient as well as a family of curves associated with an additional soft-start capacitor. The soft-start capacitor is placed across VR2 and can range in value from 10 uF to 47 uF as shown. Line frequency ripple voltage for the 5 V output is shown in Figure 14 for 115 VAC input and 15 W output. Switching frequency ripple voltage on the 5 V output is shown in Figure
105
15 for the same test condition Line frequency and switching frequency ripple for the 3.3 V output are shown in Figures 17 and 18, respectively. The 5 V output transient response to a step load change from 2.25 to 3 A (75% to 100%) is shown in Figure 19. Note that the response is quick and well damped. The initial voltage spike in response to the load step is due to the interaction of the load current with the ESR of C3. If desired, the amplitude of this spike can be reduced by substituting a low ESR capcitor for C3. The RD6 is designed to meet worldwide safety and EMI (VDE B) specifications. Measured conduction emissions are shown in Figure 20 for 115 VAC and Figure 21 for 230 VAC.
Transformer Specification
The electrical specifications and construction details for transformer TRD6 are shown in Figures 22 and 23. Transformer TRD6 is supplied with the RD6 reference design board. This design utilizes an EI25 core and a triple insulated wire secondary winding. The use of triple insulated wire allows the transformer to be constructed using a smaller core and bobbin than a conventional magnet wire design due to the elimination of the margins required for safety spacing in a conventional design. If a conventional margin wound transformer is desired, the design of Figures 24-25 can be used. This design (TRD6-1) uses a EEL22 core and bobbin to accommodate the 3 mm margins required to meet international safety standards when using magnet wire rather than triple insulated wire, and has the same pinout and printed circuit foot print as TRD6. The transformer is approximately 50% taller than the triple insulated wire design due to the inclusion of creepage margins required to meet international safety standards.
105
3.3V Output Voltage (% of Nominal)
5V Output Voltage (% of Nominal)
VIN = 115 VAC 100
VIN = 115 VAC 100
95
0
1.0
2.0
3.0
95 0 0.5 0.1
Load Current (A)
105 VIN = 230 VAC 100
Load Current (A)
105 VIN = 230 VAC 100
95
95
0
1.0
2.0
3.0
0
0.5
0.1
Load Current (A)
Figure 6. Load Regulation
Load Current (A)
4
B 3/98
PI-2147-012398
RD6
3.3V Output Voltage (% of Nominal) 5V Output Voltage (% of Nominal)
PI-2151-011598
105
105
5V @ 3.0A and 3.3V @ 0.1A
5V @ 3.0A and 3.3V @ 0.1A
100
100
95
50
100
150
200
250
300
95
50
100
150
200
250
300
Input Voltage (VAC)
105 5V @ 0.53A and 3.3V @ 0.1A 100
Input Voltage (VAC)
105 5V @ 0.53A and 3.3V @ 0.1A 100
95
50
100
150
200
250
300
95
50
100
150
200
250
300
Input Voltage (VAC)
Figure 7. Line Regulation
100 Po = 15.3 W 100
Input Voltage (VAC)
PI-2153-011598
Po = 3 W
Output Efficiency (%)
60
Output Efficiency (%)
80
80
60
40 20
40 20
0 0 100 200 300
0 0 100 200 300
Input Voltage (VAC)
Input Voltage (VAC)
Figure 8. Efficiency vs. Input Voltage, 15.3 W Output
Figure 9. Efficiency vs. Input Voltage, 3 W Output
PI-2159-011598
VIN = 115 VAC
VIN = 230 VAC
Output Efficiency (%)
Output Efficiency (%)
80
80
60
60
40 20
40 20
0 0 5 10 15 20
0 0 5 10 15 20
Output Power (W)
Figure 10. Output Efficiency vs. Output Power, 115 VAC Input
Output Power (W)
Figure 11. Output Efficiency vs. Output Power, 230 VAC Input
B 3/98
PI-2161-011598
100
100
PI-2157-011598
5
RD6
PI-2163-011998
PI-2165-011998
DC BUS VOLTAGE
150 100 50 0 6 4 2 0 0 100
OUTPUT VOLTAGE
Output Voltage (V)
6 0 F 4 2 0
10 F 22 F 47 F
200
0
100
200
Time (ms)
Figure 12. Turn On Delay
80 60
Time (ms) Figure 13. Output Voltage Turn On Transient vs Soft Start Capacitor
80 60
PI-2169-012098
Output Voltage (mV)
20 0 -20 -40 -60 -80 0 25 50
Output Voltage (mV)
40
40 20 0 -20 -40 -60 -80 0 25
50
Time (ms)
Time (s)
Figure 14. 5V LineFrequency Ripple, 115 VAC Input, 15.3 W Output
PI-2173-012098
Figure 15. 5 V Switching Frequency Ripple, 115 VAC Input, 15.3 W Output
PI-2175-012098
80 60
80 60
Output Voltage (mV)
Output Voltage (mV)
40 20 0 -20 -40 -60 -80 0 25
40 20 0 -20 -40 -60 -80
50
0
25
50
Time (ms)
Time (s)
Figure 16. 3.3 V Line Frequency Ripple, 115 VAC Input, 15.3 W Output
Figure 17. 3.3 V Switching Frequency Ripple, 115 VAC Input, 15.3 W Output
6
B 3/98
PI-2171-012098
RD6
20
Output Current (A) Output Voltage (mV)
0 -20 -40 -60
3.0 2.0 1.0
0
10
20
Time (ms)
Figure 19. 5 V Transient Load Response (75% to 100% Load)
PI-2179-012398
PI-2177-012198
40
100
VDE B Limit (VFG243A)
100
VDE B Limit (VFG243A)
Amplitude (dBmV)
80 60 40 20 0 0.01 0.1 1 10
Amplitude (dBmV)
80 60 40 20 0 0.01 0.1 1 10
Frequency (MHz)
Figure 20. EMI Characteristics at 115 VAC Input
Frequency (MHz)
Figure 21. EMI Characteristics at 230 VAC Input
B 3/98
PI-2181-012398
7
RD6
8 1 62 T #30 AWG 2 3 7T 2x #30 AWG 4
5
7, 8 3T 4x #24 AWG Triple-insulated 5, 6
PIN 1 2 3 4 5, 6 7, 8
FUNCTION HIGH-VOLTAGE DC BUS TOPSwitch DRAIN PRIMARY-SIDE COMMON VBIAS RETURN OUTPUT
1
4
CORE# - PC40 EI25-Z (TDK) GAP FOR AL OF 245 nH/T2 BOBBIN# - BE-25-118CP (TDK)
ELECTRICAL SPECIFICATIONS
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance 60 Hz, 1 minute, from pins 1-4 to pins 5-8 Between pins 1-4 and pins 5-8 Between Pins 1-2 (All other windings open) Between Pins 1-2 (All other windings open) Between Pins 1-2 (Pins 5-8 shorted) 3000 VAC 6.0 mm (min) 980 H, 10% 700 KHz (min) 40 H (max)
NOTE: All inductance measurements should be made at 100 kHz
PI-2139-121897
Figure 22. Electrical specification of transformer TRD6
8
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RD6
TAPE
5 6 8 7 3 4 1 2
SECONDARY BIAS PRIMARY
WINDING INSTRUCTIONS
Primary (2 layers) Start at pin 2. Wind 62 turns of #30 AWG heavy nyleze magnet wire in two layers. Finish on Pin 1 1 layer of 10.8 mm wide polyester tape for basic insulation. Start at Pin 4. Wind 7 turns of 2 parallel strands of #30 AWG heavy nyleze magnet wire. Space turns evenly across bobbin to form a single layer. Finish on Pin 3. 1 layer of 10.8 mm wide polyester tape for basic insulation. Start at Pins 7 and 8. Wind 3 quadrifilar turns of #24 AWG Triple Insulated Wire. Finish on Pins 5 and 6. 3 layers of 10.8 mm wide polyester tape for insulation. Assemble and secure core halves. Impregnate uniformly using varnish.
Basic Insulation Bifilar Bias Winding
Basic Insulation 24 V Double Bifilar Secondary Winding Outer Insulation Final Assembly
* Triple insulated wire sources. P/N: T28A01TXXX-3 Rubudue Wire Company 5150 E. La Palma Avenue Suite 108 Anaheim Hills, CA 92807 (714) 693-5512 (714) 693-5515 FAX P/N: order by description Furukawa Electric America, Inc. 200 Westpark Drive Suite 190 Peachtree City, GA 30269 (770) 487-1234 (770) 487-9910 FAX P/N: order by description The Furukawa Electric Co., Ltd 6-1, Marunouchi 2-chome, Chiyoda-ku, Tokyo 100, Japan 81-3-3286-3226 81-3-3286-3747 FAX
PI-2145-121897
Figure 23. Construction details of transformer TRD6
B 3/98
9
RD6
8 1 62 T #30 AWG 2 3 7T 2x #30 AWG 4
5
7, 8 3T 4x #24 AWG 5, 6
PIN 1 2 3 4 5, 6 7, 8
FUNCTION HIGH-VOLTAGE DC BUS TOPSwitch DRAIN PRIMARY-SIDE COMMON VBIAS RETURN OUTPUT
1
4
CORE# - PC40 EE22/29/6-Z (TDK) GAP FOR AL OF 145 nH/T2 BOBBIN# - YC 2204 (Ying Chin)
ELECTRICAL SPECIFICATIONS
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance 60 Hz, 1 minute, from pins 1-4 to pins 5-8 Between pins 1-4 and pins 5-8 Between Pins 1-2 (All other windings open) Between Pins 1-2 (All other windings open) Between Pins 1-2 (Pins 5-8 shorted) 3000 VAC 6.0 mm (min) 840 H, 10% 700 KHz (min) 40 H (max)
NOTE: All inductance measurements should be made at 100 kHz
PI-2143-121897
Figure 24. Electrical specification of transformer TRD6-1
10
B 3/98
RD6
5, 6 7, 8 TAPE 3 4
SECONDARY BIAS TAPE MARGINS PRIMARY
1 2 SLEEVING
WINDING INSTRUCTIONS
Primary Margins Tape margins with 3 mm wide polyester tape. Match height with primary and bias windings. Start at pin 2. Wind one layer (approximately 38 turns) of 30 AWG heavy nyleze magnet wire from bottom (pin side) to top. Use one layer of 12.2 mm wide polyester tape over first primary layer for basic insulation. Continue winding remaining primary turns from top to bottom. Finish on Pin 1. Sleeve start and finish with 24 AWG Teflon sleeving. Use 1 layer of 12.2 mm wide tape for basic insulation. Start at Pin 4. Wind 7 bifilar turns 30 AWG heavy nyleze magnet wire from bottom to top. Spread turns evenly across bobbin. Finish on Pin 3. Sleeve start and finish leads with 24 AWG Teflon sleeving. Use 3 layers of 18.2 mm wide polyester tape for reinforced insulation. Tape margins with 3 mm wide polyester tape. Match height with secondary winding. Start at Pins 7 and 8. Wind 3 quadrifilar turns of 24 AWG heavy nyleze magnet wire from bottom to top. Spread turns evenly across bobbin. Finish on Pins 5 and 6. Sleeve start and finish leads with 24 AWG Teflon sleeving. Apply 3 layers of 18.2 mm wide polyester tape for outer insulation. Assemble and secure core halves. Impregnate uniformly with varnish.
PI-2141-121897
Primary Windings
Basic Insulation Bias Winding
Reinforced Insulation Secondary Windings
12V Secondary Winding
Outer Insulation Final Assembly
Figure 25. Construction details of transformer TRD6-1
B 3/98
11
RD6
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein, nor does it convey any license under its patent rights or the rights of others. PI Logo and TOPSwitch are registered trademarks of Power Integrations, Inc. (c)Copyright 1998, Power Integrations, Inc. 477 N. Mathilda Avenue, Sunnyvale, CA 94086 http://www.powerint.com
WORLD HEADQUARTERS Power Integrations, Inc. 477 N. Mathilda Avenue Sunnyvale, CA 94086 USA Main: +1*408*523*9200 Customer Service: Phone: +1*408*523*9265 Fax: +1*408*523*9365 EUROPE & AFRICA Power Integrations (Europe) Ltd. Mountbatten House Fair Acres Windsor Berkshire SL4 4LE, United Kingdom Phone: +44*(0)*1753*622*208 Fax: +44*(0)*1753*622*209 TAIWAN Power Integrations International Holdings, Inc. 2F, #508, Chung Hsiao E. Rd., Sec. 5, Taipei 105, Taiwan Phone: +886*2*727*1221 Fax: +886*2*727*1223 INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore 560052, India Phone: +91*80*226*6023 Fax: +91*80*228*2191
JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222, Japan Phone: +81*(0)*45*471*1021 Fax: +81*(0)*45*471*3717
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
ASIA & OCEANIA For Your Nearest Sales/Rep Office Please Contact Customer Service Phone: +1*408*523*9265 Fax: +1*408*523*9365
APPLICATIONS HOTLINE World Wide +1*408*523*9260 APPLICATIONS FAX Americas +1*408*523*9361 Europe/Africa +44*(0)*1753*622*209 Japan +81*(0)*45*471*3717 Asia/Oceania +1*408*523*9364
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