View EPR-32_1237478.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

Title
Engineering Prototype Report for EP-32 - TOPSwitch(R)-GX 25 W Multiple Output DVD, Set-top Box Power Supply Using TOP245P 85 VAC to 265 VAC Input, 3.3 V, 5 V, 12 V, -24 V, 20 W continuous / 25 W peak output DVD player, Set-top box and other multiple output applications Power Integrations Applications Department EPR-32 13-Jul-06 1.1
Specification Application Author Document Number Date Revision
Summary and Features * * * * * * * Low parts count, low cost design Excellent cross-regulation without linear post-regulators Simple input EMI filter Meets EN55022 B / CISPR22 B EMI with >20 dB margin Low no-load input power (<65 mW at 115 VAC, <90 mW at 230 VAC) High standby efficiency, <0.9 W input power with 0.5 W load High efficiency, >75%
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-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
Table Of Contents
Introduction.................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic...................................................................................................................5 Circuit Description ......................................................................................................6 4.1 Input EMI Filtering ...............................................................................................6 4.2 TOPSwitch-GX Primary.......................................................................................6 4.3 Output Rectification .............................................................................................7 4.4 Output Feedback and Control .............................................................................7 4.5 Secondary 3.3 V and 5 V Shunt Regulator..........................................................8 5 PCB Layout ................................................................................................................9 6 Bill Of Materials ........................................................................................................10 7 Transformer Specification.........................................................................................12 7.1 Electrical Diagram .............................................................................................12 7.2 Electrical Specifications.....................................................................................12 7.3 Materials............................................................................................................13 7.4 Transformer Build Diagram ...............................................................................13 7.5 Transformer Winding Construction....................................................................14 7.6 Bobbin Drawing .................................................................................................15 8 Transformer Spreadsheet.........................................................................................16 9 Performance Data ....................................................................................................18 9.1 Efficiency ...........................................................................................................18 9.2 No-load Input Power..........................................................................................19 9.3 Regulation .........................................................................................................20 10 Thermal Performance ...........................................................................................21 11 Waveforms............................................................................................................22 11.1 Drain Voltage and Current Waveforms..............................................................22 11.2 Output Voltage Start-up Profile..........................................................................23 11.3 Load Transient Response .................................................................................23 11.4 Output Ripple Measurements............................................................................25 11.4.1 Ripple Measurement Technique ................................................................25 11.4.2 Measurement Results ................................................................................26 12 Control Loop Gain/Phase Measurements .............................................................27 12.1 115 VAC Maximum Load...................................................................................27 12.2 115 VAC 50% Load...........................................................................................27 12.3 115 VAC Minimum Load....................................................................................28 12.4 230 VAC Maximum Load...................................................................................28 12.5 230 VAC 50% Load...........................................................................................29 12.6 230 VAC Minimum Load....................................................................................29 13 Conducted EMI .....................................................................................................30 14 Revision History ....................................................................................................32 Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
1 2 3 4
Page 2 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
1 Introduction
This document is an engineering report describing the design of an AC-DC power supply with universal input and 4 outputs. The design, rated for 20 W (25 W peak), is implemented using a TOP245P device from the TOPSwitch-GX IC family and an EEL25 core in a flyback topology. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
Figure 1 - Populated Circuit Board Photograph.
Page 3 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power 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 Total Output Power Continuous Peak Efficiency Environmental Conducted EMI Safety Surge Ambient Temperature TAMB 2 0 Meets CISPR22B / EN55022B Designed to meet IEC950/UL1950 Class II 3 50 kV
o
Symbol VIN fLINE
Min 85 47
Typ 100/115/230 50/60
Max 265 64 0.1 3.45 50 2.0 5.25 75 2.5 12.84 100 500 -26.9 100 50
Units VAC Hz W V mV A V mV A V mV mA V mV mA W W %
Comment
2 Wire (No Protective Earth Ground) Measured at 265 VAC 5% 20 MHz Bandwidth 5% 20 MHz Bandwidth 7% 20 MHz Bandwidth -10% / +12% 20 MHz Bandwidth
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 POUT POUT_PEAK
3.20 0.30 4.75 0.30 11.16 100 -21.62 30 4.4
3.30 0.60 5.00 1.20 12.00 200 -24.00 50 20
25 75
Measured at POUT (26 W), 25 C
o
1.2 / 50 s surge, IEC 1000-45, Series Impedance: Differential Mode: 2 Common Mode: 12 Free convection, sea level
C
Table 1 - Power Supply Specification.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 4 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
3 Schematic
Figure 2 - Schematic.
Page 5 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
4 Circuit Description
This design features the TOP245P device from the TOPSwitch-GX IC family. By using the PC board to provide heatsinking, the need for an external heatsink is eliminated, removing the cost of the heatsink and associated assembly costs. To provide <0.1 W no-load consumption, current mode control with variable frequency operation is implemented using the X pin feature of the TOPSwitch-GX. In designs where 0.5 W no-load is acceptable, the X pin control components can be removed, relying on the standard voltage mode control via the CONTROL pin. More details of this operation is provided below. An optional secondary side discrete shunt regulator provides a low cost and efficient (no heatsink required) method of meeting the tight regulation requirements of maximum load on either the 5 V or 3.3 V outputs while the other is at minimum load. In designs where the minimum and maximum loads on the 3.3 V and 5 V output occur at the same time, this circuit can easily be removed. 4.1 Input EMI Filtering Conducted EMI filtering is provided by C3, C1, L1, and C4. The switching frequency jitter feature of the TOPSwitch-GX family allows the use of a small, low cost common mode choke for L1 and reduces the value of C3 needed to meet EN55022 / CISPR22 Class B with good margin. A safety rated Y capacitor bridges the isolation barrier from the rectified DC rail to output return. This returns common mode EMI currents generated by the primary and secondary switching waveforms, reducing conducted EMI. EMI results are presented in a later section of this document. Returning the Y capacitor to the DC rail ensures high currents present during line transients are routed away from U1. 4.2 TOPSwitch-GX Primary The universal AC input (85 VAC to 265 VAC) is rectified and filtered by D1-D4, C1 and C2. To limit inrush current and prevent damage to D1-D4, a thermistor RT1 is used. In addition, an MOV (or VDR), RV1, provides differential surge protection. The rectified DC rail is applied to one end of the transformer primary, the other end being connected to the DRAIN pin of the integrated MOSFET of U1. To keep the peak DRAIN voltage acceptably below the BVDSS (700 V) of U1, diode D5, R7, VR1, C2, and R1 form a primary clamp. This network clamps the voltage spike seen on the DRAIN due to primary and secondary reflected leakage inductance. Capacitor C2 together with R1 form the main clamp with VR1 providing a hard limit for the maximum voltage seen across the primary. Resistor R7 ensures that VR1 only conducts at the end of the leakage inductance spike event, limiting dissipation. Diode D5 is deliberately selected as a slow recovery type, but must be a glass-passivated type to guarantee the reverse recovery time as defined by the manufacturer. Standard 1N4007 diodes should not be used as their potential for very long reverse recovery times can cause excessive
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 6 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
drain ringing. The slow recovery time, compared to fast or ultra-fast diodes, allows recovery of some of the clamp energy, improving efficiency. 4.3 Output Rectification The secondary of the transformer is rectified and filtered by D7, C15, D11, C11, D10, C12, D12, and C9. For better voltage centering and regulation, the 12 V output is DC stacked on top of the 5 V output; the start of the 12 V winding is connected to the cathode of D11. A small ferrite bead, L5, was used to center the output and improve crossregulation by reducing the effect of secondary leakage inductance. Post-filters (L2, C20, L3, C17, L4, C16, R8, and C6) remove switching noise and further reduce switching ripple. 4.4 Output Feedback and Control DC feedback to the output voltage regulator error amp (U3) comes from a combination of the 3.3 V output, via R12, and 5 V output, via R11. Together with resistor R9, these form a resistor divider, the center point that is tied to the 2.5 V REF pin of U3. Capacitor C14 and R10 roll off the high frequency gain of U3 while R17 sets the overall DC gain. In a TOPSwitch-GX design, regulation of the output is normally provided by voltage mode PWM control. The current into the CONTROL pin sets the duty cycle of the internal MOSFET. The duty cycle control operates over a CONTROL pin current of 2 mA to 6 mA. Current below this level is used to supply power to the IC. In this design control is accomplished by employing the externally programmable current limit function of the TOPSwitch-GX family, in this case via the M pin. This implements current mode control rather than using voltage mode PWM control via the CONTROL pin. The first ~2 mA of feedback current is fed into the CONTROL pin. This provides the supply current for operation, but leaves the duty cycle at the internal device maximum. Feedback current above ~2 mA forward biases Q3 and pulls up R6 via R4. The characteristic of the M pin is such that increasing sink current (current out of the pin) increases the primary current limit. Therefore, as the feedback current increases, the sink current decreases and the primary current limit reduces, thereby allowing the output voltage feedback loop to control the primary peak current. Resistor R6 sets the peak current limit (startup and overload) and R4 ensures that the maximum source current (current into the M pin) stays below 44 A to prevent the device from operating in the line sensing mode of the M pin. As any current above 2 mA engages the M pin control, the current into the CONTROL pin is limited to this level and therefore, the PWM function of the CONTROL pin does not determine the duty cycle. As the load is reduced, the primary current limit reduces until the remote ON/OFF (inhibit) threshold is reached at an M pin sink current of approximately 27 A. The supply then operates with a fixed 25% current limit, but at a reduced and variable switching frequency,
Page 7 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
to maintain regulation as the load is further reduced. This greatly reduces switching losses, maintaining high standby efficiency and low no-load power consumption. Current mode control above 50% duty cycle requires slope compensation and this is provided by a ramp signal generated from the bias winding via R2 and C16. Capacitor C16 also serves as a high frequency roll-off filter. The gain/phase results presented (Section 12) show excellent margin under all operating conditions. 4.5 Secondary 3.3 V and 5 V Shunt Regulator To meet the cross-regulation requirement of the 3.3 V output at maximum load while the 5 V output is at minimum load or vice versa, a low cost secondary side shunt regulator was added between the 3.3 V and 5 V outputs. This is formed by R14, R13, Q5, R16, R15, Q4, Q1, D8, and D9. This provides current from the 5 V output into the 3.3 V output when the voltage difference between the two outputs becomes unacceptable. This threshold is set by R14, R15 and Q5, which in turn drive Q4 and Q1, providing current to the 3.3 V output via D8 and D9. Unlike a linear regulator, this circuit dissipates very little power and the addition of D8 and D9 reduces the dissipation in Q1 such that no heatsink is required at all. The circuit configuration provides enough temperature compensation to meet the 0 C to 50 C ambient temperature specification. In applications where the 3.3 V and 5 V loads track (the minimum and maximum loads on both outputs occur at the same time) then this circuit may be removed. Note that this circuit is not needed to meet no-load regulation.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 8 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
5 PCB Layout
Figure 3 - Printed Circuit Layout (0.001 inches).
Page 9 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
6 Bill Of Materials
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 1 2 2 2 1 2 1 6 1 1 1 1 2 1 1 3 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 Reference C1, C4 C3 C2 C6, C9 C8 C11, C12 C5, C13 C14, C16 C15 C17, C18 C20 D1, D2, D3, D4, D8, D9 D5 D6 D7 D12 D10, D11 F1 L1 L2, L3, L4 L5 Q1 Q3, Q5 Q4 R1 R2 R3 R4 R6 R7 R8 R9 R10 R11 R12 Description 33 F, 400 V 18 mm x 20 mm 0.047 F, 250 VAC, X class 0.01 F, 1 kV ceramic disc 150 F, 35 V, low ESR 8 mm x 11.5 mm, 117 m 2.2 nF, Y1 Class 1200 F, 10 V 10 mm x 20 mm, 23 m 47 F, 25 V, general purpose 5 mm x 11 mm 0.1 F, 50 V, ceramic 470 F, 25 V, low ESR 10 mm x 16 mm, 68 m 470 F, 10 V, low ESR 8 mm x 11.5 mm, 117 m 180 F, 25 V, low ESR 8 mm x 11.5 mm, 117 m 1 A, 600 V, rectifier 1 A, 1000 V, trr = 2 s glass passivated rectifier 1N4148, 75 V, signal 1 A, 40 V, Schottky 1 A, 200 V, ultra-fast 5 A, 40 V, Schottky 3.15 A, 250 VAC 5 mH, 0.3 A common mode choke 5.5 A, 3.3 H inductor Ferrite bead 2SA0885, PNP TO-92 Transistor / PNP TO-92 Transistor / NPN 68 , 1/2 W, 5% 18 k, 1/4 W, 5% 270 , 1/4 W, 5% 10 k, 1/4 W, 5% 5.1 k, 1/4 W, 5% 1 k, 1/4 W, 5% 1 , 1/2 W, 5% 10 k, 1/4 W, 1% 3.3 k, 1/4 W, 5% 20 k, 1/4 W, 1% 6.34 k, 1/4 W, 1% P/N EEU-EB2G330S ECQ-U2A473MV 5HKS10 EEU-FC1V151 ECK-DNA222ME KZE10VB122M10X20LL ECA-1EHG470 ECU-S1H104MEA EEU-FC1E471 EEU-FC1A471 EEU-FC1E181 1N4005 1N4007GP 1N4148 1N5819 UF4003 SB540 3721315041 HT9V03050 622LY-3R3M 2643001501 2SA0885 2N3906_D26Z 2N3904_D26Z CFR-50JB-68R CFR-25JB-18K CFR-25JB-270R CFR-25JB-10K CFR-25JB-5K1 CFR-25JB-1K0 CFR-50JB-1R0 MFR-25FBF-10K0 CFR-25JB-3K3 MFR-25FBF-20K0 MFR-25FBF-6K34 Manufacturer Panasonic Any Vishay / Cera-mite Panasonic Pansonic United Chemi-con Panasonic Panasonic Panasonic Panasonic Panasonic Any General Semiconductor (Vishay) Any Any Any General Semiconductor Wickmann CUI Toko Fair-Rite Panasonic Fairchild Fairchild Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 10 of 36
13-Jul-06
36 37 38 39 40 41 42 43 44 45 46 47 48 2 1 1 1 1 1 1 1 1 1 1 1 1 R13, R16 R14 R15 R17 VR1 RV1 RT1 TI U1 U3 U2 J1 J2 2 k, 1/4 W, 1%
EPR-32 - 25 W Multiple Output TOP245P Supply
MFR-25FBF-2K00 MFR-25FBF-1K13 CFR-25JB-2K4 CFR-25JB-200R P6KE130A ERZ-V14D431 CL-120 SIL6025 LSPA11218 5450122600 TOP245P TL431ALCP LTV817A 26-48-1031 26-48-1081 Yageo Yageo Yageo Yageo Any Panasonic Thermometrics Hical Li Shin Vogt Power Integrations Fairchild Lite-On Molex Molex
1.13 k, 1/4 W, 1% 2.4 k, 1/4 W, 5% 200 , 1/4 W, 5% Zener / TVS, 3 W, 130 V Varistor 430 VDC, 110 J (2 ms) Thermistor EEL25 Flyback Transformer TOPSwitch-GX, P package Reference Opto coupler 80-160% CTR Input connector Output connector
Page 11 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
7 Transformer Specification
7.1 Electrical Diagram
1 8
W2 Primary 63T
4T
12 NC 4 7
W8 +12 V
4T
13
W4 Shield 2
W3 Bias
5
6T 1T
9 NC
W6 +5 V
W1 Shield 1
1
W5 32T 2T
10, 11
+3.3 V
W7 13T
14
-24 V
Figure 4 -Transformer Electrical Diagram.
7.2
Electrical Specifications
1 second, 60 Hz, from pins 1 through 7 to pins 8 through 14 Pin 1 to pin 4, all other windings open, measured at 132 kHz, 1 V RMS excitation Pin 1 to pin 4, all other windings open, 1 V RMS excitation Pin 1 to pin 4, with pins 8 thru 14 shorted, measured at 132 kHz, 1 V RMS 3000 VAC 800 H, +/-10% 300 kHz (min.) 80 H (max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 12 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description Core: EEL25, TDK gapped for AL of 202 nH/T2 Bobbin: EEL25 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 Varnish
7.4
Transformer Build Diagram
Pin Side
8 12 10 14 13 9 11 13 7 5 4 1 1 NC Shield 1 Shield 2 NC +12 V -24 V
+3.3 V and +5 V
Bias Primary
NC = No connection to a pin
Figure 5 - Transformer Build Diagram.
The following figure shows the copper foils to be used for +3.3 V and +5 V outputs (W5 and W6)
Finish Pin 13
#26 Copper Wire
60 mm
Connect Pin 9
#26 Copper Wire
90 mm
Start Pin 11
Tape
+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 - Copper Foil Winding Information.
Page 13 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
7.5
Transformer Winding Construction
Margin Tape
W1 First Shield Basic Insulation W2 Two Layers Primary Basic Insulation W3 Bias Insulation Margin Tape W4 Second shield. Insulation W5 and W6 +3.3 V and +5 V outputs. Basic Insulation W7 -24 V output. Basic Insulation W8 +12 V output Outer Insulation Core Assembly Final Assembly
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 1 using item [4] at the finish leads. Cut the starting lead just at the start 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 left to right. Apply one layer of item [6]. Continue the same wire on second layer. Wind 31 turns from right to left. 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 5 using item [4] at the start leads. Wind 6 turns of 4 parallel wires of item [3]. Wind from left to right in a single layer. The wires should be tightly and uniformly wound. Finish on pin 7 using item [4] at the finish leads. 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 4 turns of 4 parallel wires of item [3]. Wind from right to left in a single tightly wound layer. Cut the ending lead to finish the winding. Apply one layer of tape item [6] Prepare copper foil item [5] and item [7] as shown in Figure 1. 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 and 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 13 turns of 2 parallel wires of item [3]. Wind from right to left in a uniform and tightly wound layer. Finish on pin 10 using item [4] at the finish leads. Apply one layer of tape item [6] Start on pin 12 using item [4] at the start leads. Wind 4 turns of 4 parallel wires of item [3]. Wind from right to left in a single tightly wound layer. Finish on pin 8 using item [4] at the finish leads. 3 layers of tape [7] for insulation. Assemble and secure core halves. Item [1] Dip varnish uniformly in item [9]. Do not vacuum impregnate.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 14 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
7.6
Bobbin Drawing
Figure 7 - EP-32 Transformer Bobbin Drawing.
Page 15 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
8 Transformer Spreadsheet
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 16 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
The warning shown for PO is accepted as the 25 W specified power is a peak requirement (thermally limited). The warning shown for CMA (primary wire current density) is also accepted as it indicates the primary wire current density is low, and a smaller wire gauge could be used. The final design used bifilar 32 AWG wire.
Page 17 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency
90%
85%
80%
75%
Efficiency
70%
65% 85 VAC 115 VAC 230 VAC
60%
55%
50% 0 5 10 15 20 25 30
Output Power (W)
Figure 8 - Output Power vs. Efficiency, Room Temperature, 60 Hz.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 18 of 36
13-Jul-06 9.2 No-load Input Power
100 90 80 70
EPR-32 - 25 W Multiple Output TOP245P Supply
Input Power (mW)
60 50 40 30 20 10 0 80 100 120 140 160 180 200 220 240 260 280
Input Voltage (VAC)
Figure 9 - No-Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
1
0.95
Input Power (W)
0.9
0.85
0.8
0.75 80 100 120 140 160 180 200 220 240 260 280
Input Voltage (VAC)
Figure 10 - Input Power vs. Input Voltage, 0.5 W Load, Room Temperature, 60 Hz.
Page 19 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
9.3 Regulation All outputs were taken from minimum to maximum loads (per Table 1) according to the table below. The resultant overall variation in the output voltages is shown in Table 3.
-24 V M m m M M M 3.3 V M M m m M m 5V M M m M m m 12 V M M M M M M -
M = Max load, m = Min load, - = Unloaded
Table 2 - Load Conditions for Cross-regulation Results.
Regulation (% of nominal)
Output Results -2.1% to -0.9% -3.6% to +2.2% -4.4% to +5% -3.8% to +8% -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8
3.3 V 5V 12 V -24 V
Table 3 - Cross-regulation Results.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 20 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
10 Thermal Performance
The temperature of key components was measured at the maximum specified ambient of 50 C. In addition to checking for hotspots, an infrared thermograph was taken at room ambient (as this is output as a color profile, please use the color version of this document, available at www.powerint.com/epr.htm, to review the temperatures).
Temperature (C) Item Ambient Common Mode (L1) Transformer (T1) TOPSwitch-GX (U1) 5 V Rectifier (D11) 3.3 V Rectifier (D10) 90 VAC 115 VAC 230 VAC
51 90 85 102 112 107
51.4 82 79 93 112 99
51 67 83 80 113 98
Table 4 - Temperature of Key Components, 50 C Ambient.
Figure 11 - Infrared Thermograph (with silk screen overlaid) of EP-32, 90 VAC Input, 20 W Load (5 V at 2 A, 3.3 V at 2 A, 12 V at 0.28 A, -24 V at 0 A), 23 C Ambient.
In order to make the thermograph representative of the actual component temperatures, the entire board was spray painted black to give a uniform emissivity value. The thermograph shows the hottest parts to be the input thermistor RT1, TOP245P, VR1, R1 in the clamp, and D11, the 5 V output diode. The highest temperature measured was 80 C on R1, however, all components would remain acceptably less than 110 C in an ambient of 50 C.
Page 21 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
11 Waveforms
11.1 Drain Voltage and Current Waveforms
Figure 12 - 115 VAC, Full Load. Upper: VDRAIN, 100 V, 2 s / div. Lower: IDRAIN, 0.5 A / div.
Figure 13 - 230 VAC, Full Load Upper: VDRAIN, 100 V, 2 s / div. Lower: IDRAIN, 0.5 A / div.
Figure 14 - 230 VAC, 0.5 W Load Showing Reduced Frequency Operation. Upper: VDRAIN, 100 V, 10 s / div. Lower: IDRAIN, 0.5 A / div.
Figure 15 - 230 VAC, 1.5 W Load Showing Reduced Frequency Operation. Upper: VDRAIN, 100 V, 10 s / div. Lower: IDRAIN, 0.5 A / div.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 22 of 36
13-Jul-06 11.2 Output Voltage Start-up Profile
EPR-32 - 25 W Multiple Output TOP245P Supply
Figure 16 - 5 V output start-up Profile, 115 VAC, Full load. 1 V, 10 ms / div.
11.3 Load Transient Response Each output was step loaded according to the information below each of the transient response oscillograms below. All other outputs were set to maximum load.
Figure 17 - Transient Response, 115 VAC, 50-100-50% Load Step, Max Load. 3.3 V Output Voltage, 20 mV, 5 ms / div.
Figure 18 - Transient Response, 115 VAC, 60-100-60% Load Step, Max Load. 5 V Output Voltage 50 mV, 2 ms / div.
Page 23 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
Figure 19 - Transient Response, 115 VAC, 40-100-40% Load Step, Max Load. 12 V Output Voltage 100 mV, 5 ms / div.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 24 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
11.4 Output Ripple Measurements All measurements were taken at maximum load on all outputs. 11.4.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 19 and Figure 20. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 20 - Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).
Figure 21 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with Wires for Probe Ground for Ripple Measurement, and Two Parallel Decoupling Capacitors Added).
Page 25 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply 11.4.2 Measurement Results
13-Jul-06
Figure 22 - 3.3 V Ripple, 115 VAC, Full Load, 10 s, 10 mV / div.
Figure 23 - 5 V Ripple, 115 VAC, Full Load, 10 s, 10 mV / div.
Figure 24 - 12 V Ripple, 115 VAC, Full Load, 2 ms, 20 mV /div.
Figure 25 - -24 V Ripple, 115 VAC, Full Load, 5 ms, 20 mV /div.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 26 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
12 Control Loop Gain/Phase Measurements
12.1 115 VAC Maximum Load
Figure 26 - Gain-Phase Plot, 180 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 10 kHz, Phase Margin = 60.
12.2 115 VAC 50% Load
Figure 27 - Gain-Phase Plot, 180 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 13 kHz, Phase Margin = 70.
Page 27 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply 12.3 115 VAC Minimum Load
13-Jul-06
Figure 28 - Gain-Phase Plot, 180 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 8 kHz, Phase Margin = 70.
12.4 230 VAC Maximum Load
Figure 29 - Gain-Phase Plot, 230 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30 /div. Crossover Frequency = 12 kHz, Phase Margin = 50.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 28 of 36
13-Jul-06 12.5 230 VAC 50% Load
EPR-32 - 25 W Multiple Output TOP245P Supply
Figure 30 - Gain-Phase Plot, 230 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 17 kHz, Phase Margin = 62.
12.6 230 VAC Minimum Load
Figure 31 - Gain-Phase Plot, 230 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 8 kHz, Phase Margin = 70.
These results show that the X pin current mode control provides excellent bandwidth and phase margin at gain cross-over under all operating conditions.
Page 29 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
13 Conducted EMI
The results below show excellent conducted and expected radiated EMI performance (the scans were extended to 100 MHz to indicate radiated performance). In all cases >20 dB margin was measured to both Quasi-Peak (upper red traces and red limit line) and Average (lower green traces and blue limit line) limits.
Figure 32 - Conducted EMI, Maximum Load, 115 VAC, Line, 60 Hz, and EN55022 B Limits.
Figure 33 - Conducted EMI, Maximum Load, 115 VAC, Neutral, 60 Hz, and EN55022 B Limits.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 30 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply
Figure 34 - Conducted EMI, Maximum Load, 230 VAC, Line, 60 Hz, and EN55022 B Limits.
Figure 35 - Conducted EMI, Maximum Load, 230 VAC, Line, 60 Hz, and EN55022 B Limits.
Page 31 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
14 Revision History
Date 10-May-03 07-July-03 22-July-03 06-Aug-03 08-Aug-03 13-Jul-06 Author AoD AoD AoD PV IM PV Revision 0.1 0.2 0.3 0.4 1.0 1.1 Description & changes
First draft Second draft - updated transformer spec Third draft - thermal image and gain phase data added Fourth draft - formatting, circuit description added and final board photograph First release Updated Figure 2.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 32 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply Notes
Page 33 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply Notes
13-Jul-06
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 34 of 36
13-Jul-06
EPR-32 - 25 W Multiple Output TOP245P Supply Notes
Page 35 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-32 - 25 W Multiple Output TOP245P Supply
13-Jul-06
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. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) 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 grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)Copyright 2006 Power Integrations, Inc.
Power Integrations Worldwide Sales Support Locations
WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: usasales@powerint.com GERMANY Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3910 Fax: +49-89-5527-3920 e-mail: eurosales@powerint.com JAPAN Keihin Tatemono 1st Bldg 2-12-20 Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa ken, Japan 222-0033 Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com KOREA RM 602, 6FL Korea City Air Terminal B/D, 159-6 Samsung-Dong, Kangnam-Gu, Seoul, 135-728, Korea Phone: +82-2-2016-6610 Fax: +82-2-2016-6630 e-mail: koreasales@powerint.com SINGAPORE 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com TAIWAN 5F, No. 318, Nei Hu Rd., 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
CHINA (SHANGHAI) Rm 807-808A, Pacheer Commercial Centre, 555 Nanjing Rd. West Shanghai, P.R.C. 200041 Phone: +86-21-6215-5548 Fax: +86-21-6215-2468 e-mail: chinasales@powerint.com
INDIA 261/A, Ground Floor 7th Main, 17th Cross, Sadashivanagar Bangalore, India 560080 Phone: +91-80-5113-8020 Fax: +91-80-5113-8023 e-mail: indiasales@powerint.com
EUROPE HQ 1st Floor, St. James's House East Street, Farnham Surrey, GU9 7TJ United Kingdom Phone: +44 (0) 1252-730-140 Fax: +44 (0) 1252-727-689 e-mail: eurosales@powerint.com
CHINA (SHENZHEN) Room 2206-2207, Block A, Elec. Sci. Tech. Bldg. 2070 Shennan Zhong Rd. Shenzhen, Guangdong, China, 518031 Phone: +86-755-8379-3243 Fax: +86-755-8379-5828 e-mail: chinasales@powerint.com
ITALY Via Vittorio Veneto 12 20091 Bresso MI Italy Phone: +39-028-928-6000 Fax: +39-028-928-6009 e-mail: eurosales@powerint.com
APPLICATIONS HOTLINE World Wide +1-408-414-9660 APPLICATIONS FAX World Wide +1-408-414-9760
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 36 of 36

▲Up To Search▲

Price & Availability of EPR-32

	To Download EPR-32 Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .