View EPR-29_1237476.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

Title
Engineering Prototype Report for EP-29 Multiple Output 11 W (15.5 W peak) AC-DC Power Supply using TNY268P (TinySwitch-II) Universal Input, 3.3 V, 5 V, 12 V, -12 V Outputs DVD Player, Cable Box, DVB-T Receiver Power Integrations Application Department EPR-29 7-Jul-03 1.3
Specification Application Author Document Number Date Revision
Summary and Features * * * * * * Universal input operation (90 VAC to 265 VAC) High efficiency multiple output supply >79% (min.) High low-load efficiency Low parts count solution Good cross-regulation without linear post-regulators Very low cost EMI filter - no common-mode choke
The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com.
Power Integrations, Inc. 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
Table Of Contents 1 Introduction ................................................................................................................ 3 2 Power Supply Specification........................................................................................ 4 3 Schematic .................................................................................................................. 5 4 Circuit Description ...................................................................................................... 6 4.1 Input EMI Filtering............................................................................................... 6 4.2 TinySwitch-II Primary .......................................................................................... 6 4.3 Output Rectification............................................................................................. 6 4.4 Output Feedback ................................................................................................ 7 5 PCB Layout................................................................................................................ 8 6 Bill Of Materials .......................................................................................................... 9 7 Transformer Specification ........................................................................................ 10 7.1 Electrical Diagram............................................................................................. 10 7.2 Electrical Specifications .................................................................................... 10 7.3 Materials ........................................................................................................... 11 7.4 Transformer Build Diagram ............................................................................... 11 7.5 Copper Foil Preparation .................................................................................... 12 7.6 Winding Instructions.......................................................................................... 12 8 Transformer Spreadsheet ........................................................................................ 14 9 Performance Data .................................................................................................... 17 9.1 Efficiency........................................................................................................... 17 9.2 No-load Input Power ......................................................................................... 17 9.3 Standby Input Power......................................................................................... 18 9.4 Regulation......................................................................................................... 19 9.4.1 Load Regulation......................................................................................... 19 9.4.2 Line Regulation.......................................................................................... 22 10 Thermal Performance........................................................................................... 23 11 Waveforms ........................................................................................................... 24 11.1 Drain Voltage and Current, Normal Operation .................................................. 24 11.2 Output Voltage Start-up Profiles ....................................................................... 24 11.2.1 Start-up Profile for 3.3 V and 5 V Outputs.................................................. 24 11.3 Drain Voltage and Current Start-up Profile ....................................................... 25 11.4 Load Transient Response (75% to 100% Load Step) ....................................... 26 11.4.1 Transient Response for 3.3 V and 5 V Outputs ......................................... 26 11.4.2 Transient Response for +12 V and -12 V Outputs .................................... 27 11.5 Output Ripple Measurements ........................................................................... 28 11.5.1 Ripple Measurement Technique ................................................................ 28 11.5.2 Ripple Measurements at 115 VAC............................................................. 29 11.5.3 Ripple Measurements at 230 VAC............................................................. 30 11.6 Conducted EMI ................................................................................................. 31 12 Revision History.................................................................................................... 32 Important Note:
Although the EP-29 board is designed to satisfy safety isolation requirements, this engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 2 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
1 Introduction
This document is an engineering report describing an 11 W universal input, multiple output flyback power supply, utilizing a TNY268P device from the TinySwitch-II family. This power supply is intended to allow evaluation in such applications as DVD players, cable and DVB-T set-top boxes. As some applications have peak loads, accelerating a DVD disc up to speed for example, this supply will deliver 11 W continuously and up to 15.5 W peak (thermally limited). The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
Figure 1 - EP-29 Populated Circuit Board Photograph.
Note: Minimum loads are not provided on the board, hence for correct operation all outputs should be loaded according to the specification table.
Page 3 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
2 Power Supply Specification
Description Input Voltage Frequency Standby Input Power No-load Input Power Output (Normal Operation) 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 Total Output Power Continuous Output Power Peak Output Power Efficiency Output (Standby) Output Voltage 1 Output Current 1 Output Voltage 2 Output Current 2 Output Voltage 3 Output Current 3 Output Voltage 4 Output Current 4 Environmental Conducted EMI Safety Surge Ambient Temperature TAMB 2 0 50
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Symbol VIN fLINE
Min 90 47
Typ
Max 265 64 0.9 0.1 3.4 50 0.7 5.25 75 1.45 12.84 100 0.4 -12.84 100 0.1
Units VAC Hz W W V mV A V mV A V mV A V mV A W W % V A V A V mA V mA
Comment
2 Wire - no protective earth ground 0.55 W load (see below) Zero load, measured at 230 VAC 5% p-p, 20 MHz Bandwidth 5% p-p, 20 MHz Bandwidth
50/60 0.8 0.09 3.3 0.6 5 1.2 12 0.2 -12 0.05 11
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 POUT POUT_PEAK VOUT1(SB) IOUT1(SB) VOUT2(SB) IOUT2(SB) VOUT3(SB) IOUT3(SB) VOUT4(SB) IOUT4(SB)
3.2 0.3 4.75 0.5 11.16 0.1 -11.16 0.03
7% p-p, 20 MHz Bandwidth
7% p-p, 20 MHz Bandwidth
At maximum ambient temperature Thermally limited At POUT (15.5 W), 25 oC 5% 5%
15.5 75 3.2 4.75 11.16 2 -11.16 2 3.3 0.02 5 0.1 12 -12 3.4 5.25 13.2 -13.2 -
-7% / +15%
-7% / +15%
kV
o
1.2/50 s surge, IEC 1000-4-5, 2/12 series impedance, differential/common mode Free convection, sea level
C
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 4 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
3 Schematic
Figure 2 - EP-29 Schematic.
Page 5 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
4 Circuit Description
The circuit shown is an AC to DC multi-output flyback power supply using the highly integrated TNY268 power IC from the TinySwitch-II family. The circuit is designed for 90 VAC to 265 VAC input with 3.3 V, 5 V, 12 V, and -12 V outputs. 4.1 Input EMI Filtering Capacitor C3, inductor L1 and capacitors C1 and C4 provide differential mode EMI filtering. Capacitor C8 (Y-capacitor) helps to reduce common-mode and radiated EMI. In conjunction with these components, the frequency jitter feature of the TNY268 and shields in the transformer, allow the unit to pass CISPR22B/EN55022B specifications for conducted emissions without the need for a common-mode choke. 4.2 TinySwitch-II Primary Diodes D1, D2, D3, and D4 and capacitors C1 and C4 provide a high-voltage DC bus for the primary circuitry. The DC bus is applied to the high side of the transformer T1 primary winding. The other side of the transformer primary is driven by the integrated switching MOSFET of the TinySwitch-II U1. Components D5, R5, C2, R7, and VR1 form the clamp network to limit the voltage rise at MOSFET turn-off due to the transformer leakage inductance. This circuit clamps the MOSFET voltage to a safe level during normal power supply operation. The Zener VR1 actively clamps at peak output load, but does not contribute to the clamping at normal load conditions. Diode D5 is a slow-recovery diode and allows some of the clamp energy to be recovered and transferred to the output. After clamping the leakage inductance energy, diode D5 does not turn off immediately. This allows some current to flow in the reverse direction, out of C2 and couple through the transformer to the secondary side. Resistors R5 and R7 damp ringing while R5 also limits the reverse current through D5 when U1 turns on. The energy recovery of this clamp scheme contributes to slightly higher efficiency and also better cross-regulation. Diode D9 and capacitor C10 rectify and filter the voltage from the transformer bias winding. Current is fed from C10 via R6 to the BYPASS pin of U1. Supplying U1 from the bias winding reduces power consumption by inhibiting the internal DRAIN current source normally used to power the IC from the high voltage DC bus during the internal MOSFET off time. This helps improve the no-load power consumption and light load efficiency of the power supply. Capacitor C19 is the decoupling capacitor for the TinySwitch-II. Opto-transistor U2A provides feedback from the secondary side to control TinySwitch-II regulation. 4.3 Output Rectification Diodes D7, D11, D10, and D8 together with capacitors C15, C11, C12, and C9 provide rectification and filtering of the secondary transformer voltages. Capacitors C20, C17, and C18 with inductors L2, L3, and L4 provide filtering to reduce high switching frequency
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 6 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
ripple from the outputs. This is implemented with resistor R12 and capacitor C6 on the lower current -12 VDC output. 4.4 Output Feedback Resistors R15 and R16 sense the 5 V and 3.3 V outputs and with resistor R13 form a voltage divider network at the input of the TL431 (U3). Capacitor C14 provides compensation for the TL431 (to provide high DC gain but low high frequency gain). The TL431 drives current through optocopler LED U2B, which in turn is fed from the 5 V rail (before the post filter) by resistor R9. The value of R9 programs the high frequency gain of the control loop. The ON/OFF control scheme used by TinySwitch-II (U1) ensures low output ripple, fast transient response, high low-load efficiency, and low no-load consumption while minimizing audible noise by ensuring the transformer flux density is low when the switching frequency enters the audible range. Capacitor C7 provides a soft-finish characteristic to "close" the feedback loop early during power up, thus eliminating startup output overshoot. Resistor R8 provides a discharge path for C7 after power down.
Page 7 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
5 PCB Layout
Figure 3 - Printed Circuit Layout (Dimensions 0.001).
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 8 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
6 Bill Of Materials
EP-29 - TNY268 DVD 11 W (15.5 W pk) - 050203b Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Qty
2 1 1 2 2 1 1 1 2 3 2 1 4 1 2 1 2 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Reference
C1, C4 C2 C3 C6, C9 C7, C10 C8 C11 C12 C14, C19 C15 C17, C18 C20 D1, D2, D3, D4 D5 D8, D7 D9 D10, D11 F1 L1 L2, L3, L4 R5 R6 R7 R8 R9 R12 R13 R15 R16 T1 U1 U2B, U2A U3 VR1 J1
Description
P/N
Manufacturer
Nippon Chemi-Con Any Any Nippon Chemi-Con Nippon Chemi-Con Any Nippon Chemi-Con Nippon Chemi-Con Any Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Any Vishay / Any Any Any Any Any Tokin, or equiv. Toko, or equiv. Any Any Any Any Any Any Any Any Any Hical Power Integrations Isocom / Any Any Vishay / Any Molex
36 37
1 1
J2
33 F, 400 V KMG400VB33M 16 mm x 25 mm, general purpose 0.01 F, 1 kV, ceramic Z5U dielectric 0.047 F, X2 Class 220 F, 25 V KMG25VB220M 8 mm x 11.5 mm, general purpose 10 F, 50 V KMG50VB10M 5 mm x 11 mm, general purpose 1 nF, Y1 class (safety) 1800 F, 25 V, 24 m KY25VB1800MK30 12.5 mm x 30 mm, low ESR 1000 F, 10 V, 60 m KY10VB1000MJ16 10 mm x 16 mm, low ESR 0.1 F, 50 V, ceramic Z5U dielectric 470 F, 25 V, 38 m KZE25VB470MJ16 10 mm x 16 mm, low ESR 470 F, 10 V KMG10VB470M 8 mm x 11.5 mm, general purpose 100 F, 25 V KMG25VB100M 6.3 mm x 11 mm, general purpose 1 A, 600 V 1N4007 1 A, 600 V, Glass Passivated 1N4007GP UF4003 1N4148 1N5822 3.15 A, 250 VAC 1.5 mH 0.25 A SBC3-152-251 3.3 H, 2.66 A 822LY-3R3M 47 , 1/4 W, 5% 3.3 k, 1/4 W, 5% 100 , 1/2 W, 5% 1 k, 1/4 W, 5% 200 , 1/4 W, 5% 1 , 1/2 W, 5% 10 k, 1/4 W, 1% 20 k, 1/4 W, 1% 6.34 k, 1/4 W, 1% EEL25 SIL6026 TinySwitch-II TNY268P PC817A TL431AC P6KE180 Header 26-48-1031 0.156 spacing, 3 position (pull middle pin) Header 0.156 spacing, 8 position EP-29 Printed Circuit Board, Rev A
Molex
Page 9 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
7 Transformer Specification
7.1 Electrical Diagram
1 8
W2 Primary
4 6
4T x 4 64T x 2
13
W5 +12 V
W7 1T 6T x 4
9
+5 V
W3 Bias
7 NC
W6 2T +3.3 V
11, 12
W1 Shield 1
5 7
32T x 2 7T x 4 W8 -12 V
14
W4 Shield 2
NC
4T x 4
Figure 4 -Transformer Electrical Diagram.
7.2
Electrical Specifications
1 second, 60 Hz, from pins 1-7 to pins 8-14 Pins 1-4, all other windings open. Measured at 132 kHz, 1 V RMS Pin 1-4, all other windings open Pins 1-4, with pins 8-14 shorted. Measured at 132 kHz, 1 V RMS 3000 VAC 1.33 mH -0 / +15% 300 kHz (Min.) 30 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 10 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] Description 2 Core: EEL25, TDK Gapped for AL of 320 nH/T Bobbin: EEL25 Vertical 14 pins Magnet Wire: # 32 AWG Teflon Tubing # 22 Copper Foil 0.12 mm thick, 14 mm wide. Tape: 3M 1298 Polyester Film, 16.1 mm wide Tape: 3M 1298 Polyester Film, 22.1 mm wide Tape: 3M # 44 Polyester web. 3.0 mm wide Copper Tape 2.0 mils thick, 16 mm wide. Varnish
7.4
Transformer Build Diagram
Pin Side
12 14 13 9 11 8 13 7 NC 6 7 4 1 Shield 1 5 NC Bias Primary Shield 2 +3.3 V and +5 V -12 V
+12 V
NC = No Connection to a pin
Figure 5 - Transformer Build Diagram.
Page 11 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
7.5 Copper Foil Preparation The following figure shows the copper foils to be used for +3.3 V and +5 V outputs (W6 and W7)
Finish Pin 13
#26 Copper Wire
45 mm
Connect Pin 9
#26 Copper Wire
105 mm
Start Pin 11
+5 VOUT 1T Copper Foil 14.0 mm wide. 0.12 mm Thick.
+3.3 VOUT 2T Copper Foil 14.0 mm wide. 0.12 mm Thick.
Figure 6 - Foil Winding Preparation Diagram.
7.6
Winding Instructions
Set up the bobbin with its pins oriented to the right hand side. Apply 3.0 mm margin at each side of bobbin using item [8]. Match combined height of primary, shield and bias windings. Start with a floating lead. Wind 32 bifilar turns of item [3] from left to right. Wind tightly and uniformly across entire width of bobbin. Finish at pin 5 using item [4] at the finish leads. Cut the starting lead just at the starting of the winding. Apply one layer of tape item [6]. Start on pin 1 using item [4] at the start leads. Wind 32 bifilar turns of item [3] from right to left . Apply one layer of item [6]. Continue the same wire on second layer. Wind 32 turns from left to right. The two layers should be wound tightly with the turns uniformly distributed across entire width of bobbin. Finish on pin 4 using item [4] at the finish leads. Apply one layer of tape item [6]. Start on pin 7 using item [4] at the start leads. Wind 6 turns of 4 parallel wires of item [3]. Wind from right to left in a single layer. The wires should be wound tightly and uniformly spread across the bobbin width. Finish on pin 6 using item [4] at the finish leads. Apply one layer of tape item [6]. Start with a floating lead. Wind 4 turns of 4 parallel wires of item [3]. Wind from right to left in a single layer. The wires should be wound tightly and uniformly spread across the bobbin width. Finish on pin 7 using item [4] at the finish leads. Cut the starting lead just at the starting of the winding. 3 Layers of tape [7] for insulation. Apply 3.0 mm margin at each side of bobbin using item [8]. Match combined height of secondary windings. Start on pin 13 using item [4] at the start leads. Wind tightly 4 turns of 4 parallel wires of item [3]. Wind from right to left in a single spread across the bobbin width. Finish on pin 8 using item [4] at the finish leads. Apply one layer of tape item [6].
Bobbin Set Up Orientation Margin Tape
W1 First Shield Basic Insulation W2 Two Layers Primary Basic Insulation W3 Bias Basic Insulation W4 Second shield. Insulation Margin Tape W5 +12 VOUT Basic Insulation
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 12 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
Prepare copper foil item [5] and item [7] as shown in Figure 6. Start at pin 11 using item [4] at the start leads. Wind 2 turns. Connect the second lead to pin 9 using item [4] at the finish leads. Wind 1 turn. Connect the end lead to pin 13 using item [4] at the finish leads. Apply one layer of tape item [6]. Start at pin 14 using item [4] at the start leads. Wind 7 turns of 4 parallel wires of item [3]. Wind tightly from right to left in a uniform spread across the bobbin width. Finish on pin 12 using item [4] at the finish leads. 3 Layers of tape [7] for insulation. Assemble and secure core halves. Item [1]. Wind copper tape item [9] outside of core halves. Wrap the core right over the belly band with three layers item [7]. Dip varnish uniformly in item [10]. Do not vacuum impregnate. Note: vacuum impregnation may require re-optimization of shield windings for acceptable EMI performance.
W6 and W7 +3.3 V and +5 V outputs. Basic Insulation W7 -12 V output. Outer Insulation Core Assembly Belly band/ Flux band Outer Insulation Final Assembly
Page 13 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
8 Transformer Spreadsheet
Design Warning (No Optimization) Power Supply Input VACMIN VACMAX FL TC Z N Volts Volts Hertz mSeconds 90 265 50 2.21 0.52 79.0 Min Input AC Voltage Max Input AC Voltage AC Main Frequency Bridge Rectifier Conduction Time Estimate Loss Allocation Factor Efficiency Estimate
%
Power Supply Outputs VOx IOx Device Variables Device PO Watts TNY268P/G 15.56 Device Name Total Output Power Warning! Device may be too small or thermally limited for continuous power level (PO). Tip: Consider increasing device size. If P/G or Rpackage select larger device (reduce current limit via X-pin) or choose Y/F-package with appropriat Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Device On-State Drain to Source Voltage TinySwitch-II Switching Frequency TinySwitch-II Minimum Switching Frequency (inc. Jitter) TinySwitch-II Maximum Switching Frequency (inc. Jitter) Ripple to Peak Current Ratio Device Current Limit Minimum Device Current Limit Maximum Primary RMS Current Maximum Duty Cycle Volts Amps 3.30 5.00 12.00 12.00 Output Voltage 0.700 1.450 0.400 0.100 Output Current
VDRAIN
Volts
643
VDS FSNOM FSMIN FSMAX KRPKDP ILIMITMIN ILIMITMAX IRMS DMAX
Volts Hertz Hertz Hertz
2.9 132000 120000 144000 0.61 0.51 0.59 0.27 0.53
Amps Amps Amps
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 14 of 36
07-July-03
Power Supply Components Selection CIN VMIN VMAX VCLO PZ uFarads Volts Volts Volts Watts
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
66.0 107 375 170 1.8
Input Filter Capacitor Minimum DC Input Voltage Maximum DC Input Voltage Clamp Zener Voltage Estimated Primary Zener Clamp Loss
Power Supply Output Parameters VDx PIVSx ISPx ISRMSx IRIPPLEx Volts Volts Amps Amps Amps 0.5 15 2.36 1.16 0.93 0.5 23 4.90 2.41 1.92 0.7 53 1.35 0.66 0.53 0.7 Output Winding Diode Forward Voltage Drop 53 Output Rectifier Maximum Peak Inverse Voltage 0.34 Peak Secondary Current 0.17 Secondary RMS Current 0.13 Output Capacitor RMS Ripple Current
Transformer Construction Parameters Core/Bobbin Core Manuf. Bobbin Manuf LPmin NP AWG EEL25 Generic Generic uHenries 1309 64 AWG 32 Core and Bobbin Type Core Manufacturing Bobbin Manufacturing Minimum Primary Inductance Primary Winding Number of Turns Primary Wire Gauge (Rounded to next smaller standard AWG value) Primary Winding Current Capacity Reflected Output Voltage Bobbin Physical Winding Width Warning! Large bobbin width (BW) may lead to increased audio emissions. Tip: Reduce the bobbin width, or length, of the core. Consider changing to an alternate device family (if using TinySwitch-II). Safety Margin Width Number of Primary Layers Core Effective Cross Section Area Gapped Core Effective Inductance Maximum Operating Flux Density AC Flux Density for Core Curves
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
CMA VOR BW
Cmils/A Volts mm
237 118.00 22.00
M L AE ALG BM BAC
mm cm^2 nH/T^2 Gauss Gauss
3.0 1.1 0.40 319 3087 818
Page 15 of 36
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
LG LL LSEC mm uHenries nHenries 0.12 26.2 20
07-July-03
Gap Length Estimated Transformer Primary Leakage Inductance Estimated Secondary Trace Inductance
Secondary Parameters NSx Rounded Down NSx Rounded Down Vox Volts Rounded Up NSx Rounded Up Vox AWGSx Range Volts AWG 6.93 Secondary Number of Turns 6 Rounded to Integer Secondary Number of Turns 3.17 10.30 10.30 Auxiliary Output Voltage for Rounded to Integer NSx 3 7 7 Rounded to Next Integer Secondary Number of Turns 5.00 12.13 12.13 Auxiliary Output Voltage for Rounded to Next Integer NSx 23 - 27 20 - 24 25 - 29 31 - 35 Secondary Wire Gauge Range Comment: Primary wire gauge is less than recommended minimum (26 AWG) and may overheat Tip: Consider a parallel winding technique (bifilar, trifilar), increase size of transformer (larger BW) or reduce margin (M). 2.07 2 3.00 6.93 6
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 16 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. Full load is: 3.3 V, 0.7 A; 5 V, 1.6 A; +12 V, 0.4 A; -12 V, 0.1 A. 9.1 Efficiency
EP-29 Efficiency vs. Input Voltage
84% Pout = 17 W Pout = 10 W
83%
Efficiency (%)
82%
81%
80%
79%
78% 80 100 120 140 160 180 200 220 240 260 280
AC Input Voltage (V RMS)
Figure 7 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
9.2
No-load Input Power
EP-29 No-Load input power vs. Line EP-29 No-load Input Power vs. Line
100 90
No-load Input Power (mW RMS)
80 70 60 50 40 30 20 10 0 80 130 180 230 280
3.3 V and 5 V outputs unloaded 12 V and -12 V outputs 6 k
AC Input Voltage (V RMS)
Figure 8 - 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 17 of 36
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply 9.3 Standby Input Power EP-29 Standby input power vs. Line EP-29 Standby Input Power vs. Line 0.55 W Output load 0.55 W output Load
1000 950
07-July-03
No-load Input Power (mW RMS)
900 850 800 750 700 650 600 550 500 80 130 180 230 280
3.3 V, 20 mA; 5 V, 100 mA 12 V and -12 V, 2 mA
AC Input Voltage (V RMS) Figure 9 - Standby Input Power vs. Input Line Voltage, Room Temperature, 0.55 W load, 60 Hz.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 18 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
9.4
Regulation
9.4.1 Load Regulation Load regulation data was taken at four load conditions: (1) 3.3 V and 5 V min. load, (2) 3.3 V typ. load, 5 V min. load, (3) 3.3 V min. load, 5 V typ. load, and (4) 3.3 V and 5 V max. load.
EP-29 Load Regulation, 3.3 V
105% 85 VAC, 3.3 V 115 VAC, 3.3 V 230 VAC, 3.3 V 265 VAC, 3.3 V
Regulation (% of Nominal)
103%
101%
99%
97%
95% 8 10 12 14 16 18
POUT (W)
Figure 10 - Load Regulation, 3.3 V, Room Temperature.
Page 19 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
EP- 29 Load Regulation, 5 V
105% 85 VAC, 5 V 115 VAC, 5 V 230 VAC, 5 V 265 VAC, 5 V
Regulation (% of Nominal)
103%
101%
99%
97%
95% 8 10 12 14 16 18
POUT (W)
Figure 11 - Load Regulation, 5 V, Room Temperature.
EP-29 Load Regulation, +12 V
105%
85 VAC, +12 V 115 VAC, +12 V 230 VAC, +12 V 265 VAC, +12 V
Regulation (% of Nominal)
103%
101%
99%
97%
95% 8 10 12 14 16 18
POUT (W)
Figure 12 - Load Regulation, +12 V, Room Temperature.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 20 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
EP-29 Load Regulation, -12 V
105%
Regulation (% of Nominal)
103%
101%
99%
85 VAC, -12 V 115 VAC, -12 V 230 VAC, -12 V 265 VAC, -12 V
97%
95% 8 10 12 14 16 18
POUT (W)
Figure 13 - Load Regulation, -12 V, Room Temperature.
Page 21 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
9.4.2 Line Regulation
EP-29 Line Regulation, Full Load
105.0%
3.3 V 5V +12 V -12 V
Regulation (% of Nominal)
103.0%
101.0%
99.0%
97.0%
95.0% 80 100 120 140 160 180 200 220 240 260 280
AC Input Voltage (V RMS)
Figure 14 - Line Regulation, Room Temperature, Full Load.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 22 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
10 Thermal Performance
A thermal image was taken of a unit painted matt black to indicate component temperatures. In addition a thermocouple was attached at the SOURCE pins of U1 to provide a more accurate measurement. For reference the board silk screen has been overlaid.
Figure 15 - EP-29 Thermal Performance.
Ambient temperature was 23 C. The SOURCE pins of U1 were measured to be 54 C at pin 7 and 8 under typical load (11 W) and 90 VAC input. The hottest component on the board can be seen to be D11 at approximately 60 C. These results are acceptable; under high ambient conditions all components would be expected to remain below 100 C.
Page 23 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
11 Waveforms
11.1 Drain Voltage and Current, Normal Operation
Figure 16 - 115 VAC, Full Load. Upper: IDRAIN, 0.2 A, 2 s / div Lower: VDRAIN, 200 V, 2 s / div
Figure 17 - 230 VAC, Full Load Upper: IDRAIN, 0.2 A, 2 s / div Lower: VDRAIN, 200 V, 2 s / div
11.2 Output Voltage Start-up Profiles 11.2.1 Start-up Profile for 3.3 V and 5 V Outputs
Figure 18 - Start-up Profile, 115 VAC Upper plot: 5 VOUT, 2 V / div. Middle plot: 3.3 VOUT, 2 V / div. Lower plot: IDRAIN, 0.2 A, 2 s /div.
Figure 19 - Start-up Profile, 230 VAC Upper plot: 5 VOUT, 2 V / div. Middle plot: 3.3 VOUT, 2 V / div. Lower plot: IDRAIN, 0.2 A, 2 s /div.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 24 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
Figure 20 - Start-up Profile, 115 VAC Upper plot: +12 VOUT, 5 V / div. Middle plot: -12 VOUT, 5 V / div. Lower plot: IDRAIN, 0.2 A, 2 s /div.
Figure 21 - Start-up Profile, 230 VAC Upper plot: +12 VOUT, 5 V / div. Middle plot: -12 VOUT, 5 V / div. Lower plot: IDRAIN, 0.2 A, 2 s /div.
11.3 Drain Voltage and Current Start-up Profile
Figure 22 - 115 VAC Input and Maximum Load. Upper: VDRAIN, 200 V / div. Lower: IDRAIN, 0.2 A & 2 ms / div.
Figure 23 - 265 VAC Input and Maximum Load. Upper: VDRAIN, 200 V / div. Lower: IDRAIN, 0.2 A & 2 ms / div.
Page 25 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
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. 11.4.1 Transient Response for 3.3 V and 5 V Outputs
Figure 24 - Transient Response, 115 VAC, 75-100-75% Load step on 5 V Upper: 5 V Load Current, 0.5 A / div. Middle: 3.3 V output, 50 mV / div. Lower: 5 V output, 50 mV / div. All 500 s / div.
Figure 25 - Transient Response, 230 VAC, 75-100-75% Load step on 5 V Upper: 5 V Load Current, 0.5 A / div. Middle: 3.3 V output, 50 mV / div. Lower: 5 V output, 50 mV / div. All 500 s / div.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 26 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
11.4.2 Transient Response for +12 V and -12 V Outputs
Figure 26 - Transient Response, 115 VAC, 75-100-75% Load step on 5 V Upper: 5 V Load Current, 0.5 A / div. Middle: +12 V output, 50 mV / div. Lower: -12 V output, 50 mV / div. All 500 s / div.
Figure 27 - Transient Response, 230 VAC, 75-100-75% Load step on 5 V Upper: 5 V Load Current, 0.5 A / div. Middle: +12 V output, 50 mV / div. Lower: -12 V output, 50 mV / div. All 500 s / div.
Page 27 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
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 28 and Figure 29. 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 28 - Oscilloscope Probe Prepared for Ripple Measurement (end cap and ground lead removed).
Figure 29 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with wires for probe ground for ripple measurement and two parallel decoupling capacitors added).
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 28 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
11.5.2 Ripple Measurements at 115 VAC
Figure 30 - 3.3 V Ripple, 115 VAC, Full Load 2 ms, 50 mV / div. 19 mV p-p
Figure 31 - 5 V Ripple, 115 VAC, Full Load 2 ms, 50 mV / div. 52 mV p-p
Figure 32 - 12 V Ripple, 115 VAC, Full Load 2 ms, 50 mV / div. 29 mV p-p
Figure 33 - -12 V Ripple, 115 VAC, All outputs at full load. 2 ms, 50 mV / div. 42 mV p-p
Page 29 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
11.5.3 Ripple Measurements at 230 VAC
Figure 34 - 3.3 V Ripple, 230 VAC, Full Load. 2 ms, 50 mV / div. 18 mV p-p
Figure 35 - 5 V Ripple, 230 VAC, Full Load. 2 ms, 50 mV / div. 48 mV p-p
Figure 36 - 12 V Ripple, 230 VAC, Full :oad. 2 ms, 50 mV/div. 16 mV p-p
Figure 37 - -12 V Ripple, 230 VAC, Full Load. 2 ms, 50 mV/div. 40 mV p-p
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 30 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
11.6 Conducted EMI Both measurements were taken with the artificial hand input on the LISN connected to output return. The results represent the worst case with respect to line and load conditions. In both cases >10 dB margin exists indicating very acceptable performance.
Figure 26 - Conducted EMI, 15 W Peak Load, 115 VAC, 60 Hz, and EN55022 B Limits.
Figure 27 - Conducted EMI, 15 W Peak Load, 230 VAC, 60 Hz, and EN55022 B Limits.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 31 of 36
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
12 Revision History
Date 08/08/02 12/03/02 5/2/03
5/14/03 5/14/03 5/21/03 06/15/03 06/19/03 06/20/03 07/07/03
Author VC VC RM
RM RM PV IM PV PV PV
Revision 0.1 0.12 0.90
0.91 0.92 0.95 to 0.98 1.0 1.1 1.2 1.3
Description & changes Original Document. Update Transformer Document Cleaned up all pages thru transformer section. Added layout, BOM, and revised all description text. Measurements / waveforms all re-taken. New data inserts and formatted. Xfmr spreadsheet included. Doc released for review Corrected circuit description, revised spec, transformer design to meet krp limits First Release Updated BOM/Schematic to remove R10 in series with C14 - not on PCB design. Added thermal, no-load and standby data, corrected L1 on schematic, added regulation test setup description. Updated Power Supply Specification table data for the Output Current 2.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 32 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
Notes
Page 33 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
Notes
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 34 of 36
07-July-03
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
Notes
Page 35 of 36
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-29 - 4 Output, 11 W, Universal Input, DVD Supply
07-July-03
For the latest updates, visit our Web site: www.powerint.com PATENT INFORMATION 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.
The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations, Inc. PI Expert and DPA-Switch are trademarks of Power Integrations, Inc. (c) Copyright 2003, 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 e-mail: usasales@powerint.com CHINA Power Integrations International Holdings, Inc. Rm# 1705, Block A Bao Hua Bldg. 1016 Hua Qiang Bei Lu Shenzhen Guangdong, 518031 Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660
EUROPE & AFRICA Power Integrations (Europe) Ltd. Centennial Court Easthampstead Road Bracknell Berkshire RG12 1YQ, United Kingdom Phone: +44-1344-462-300 Fax: +44-1344-311-732 e-mail: eurosales@powerint.com 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 e-mail: koreasales@powerint.com
SINGAPORE Power Integrations, Singapore 51 Goldhill Plaza #16-05 Republic of Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com
TAIWAN Power Integrations International Holdings, Inc. 5F-1 No. 316 Nei Hu Road Sec. 1, Nei Hu Dist. Taipei, Taiwan 114, R.O.C. Phone: +886-2-2659-4570 Fax: +886-2-2659-4550 e-mail: taiwansales@powerint.com INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore, India 560052 Phone: +91-80-226-6023 Fax: +91-80-228-9727 e-mail: indiasales@powerint.com
JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com
APPLICATIONS FAX World Wide +1-408-414-9760
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 36 of 36

▲Up To Search▲

Price & Availability of EPR-29

	To Download EPR-29 Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .