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power integrations, inc. 5245 hellyer avenue, san jose, ca 95138 usa. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com title engineering prototype report for ep-33 ? 45 w lcd monitor external power supply using top247y ( topswitch ? -gx ) specification 90 - 265 vac input, 12 v, 3.75 a, 45 w output applications lcd monitor / tv and generic external adapter author power integrations applications department document number EPR-33 date 28-mar-03 revision 1.0 features ? high efficiency (>79% at end of cord, >83% at supply output) ? low zero load power consumption (< 0.25 w at 115 vac, < 0.3 w at 230 vac) ? <1 w input power at 0.5 w load ? meets fcc part 15b and cispr22 conducted emi with margin even with output rtn connected to protective earth ground ? design tailored to meet typical lcd monitor external supply specifications the products and applications illustrated herein (including circuits external to the products and transformer const ruction) may be covered by one or more u.s. and fo reign 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 .
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 2 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com table of contents 1 introduc tion ................................................................................................................... ........ 4 2 power supply spec ification................................................................................................... 5 3 schematic ...................................................................................................................... ....... 6 4 circuit de scription ............................................................................................................ ..... 7 4.1 input emi f iltering ......................................................................................................... 7 4.2 topswitch-gx primary................................................................................................. 7 4.3 output rectification ....................................................................................................... 7 4.4 output f eedback ........................................................................................................... 7 5 pcb layout..................................................................................................................... ...... 9 6 bill of ma terial s.............................................................................................................. ..... 10 7 transformer specification ................................................................................................... 11 7.1 electrical specifications............................................................................................... 11 7.2 materials...................................................................................................................... 11 7.3 transformer build diagram.......................................................................................... 12 7.4 transformer construction............................................................................................ 12 7.5 transformer sources................................................................................................... 12 8 transformer sp readshee t ................................................................................................... 13 9 performance data............................................................................................................... 15 9.1 efficiency..................................................................................................................... 15 9.2 no-load input power.................................................................................................... 16 9.3 input power at 0.5 w loa d .......................................................................................... 16 9.4 regulation ................................................................................................................... 17 9.4.1 load .................................................................................................................... 17 9.4.2 line ..................................................................................................................... 17 10 thermal performance...................................................................................................... 18 11 waveforms...................................................................................................................... 19 11.1 drain voltage and current, normal operation ............................................................. 19 11.2 output voltage start-up profile.................................................................................... 20 11.3 drain voltage and current start-up profile .................................................................. 21 11.4 load transient response (75% to 100% load step ) .................................................. 22 11.5 output ripple measurements ...................................................................................... 23 11.5.1 ripple measurement technique .......................................................................... 23 11.5.2 measurement results.......................................................................................... 24 12 control loop m easurement s ........................................................................................... 25 12.1 115 vac maximu m load ............................................................................................. 25 12.2 230 vac maximu m load ............................................................................................. 26 13 conducted emi ............................................................................................................... 27 14 ac surge and 100 khz rin g wave im munity .................................................................. 28 14.1 common mode surge, 1.2/50 sec................................................................................. 28 14.2 differential mode surge, 1.2/50 sec........................................................................... 28 14.3 common mode, 100 kh z ring wa ve........................................................................... 29 14.4 differential mode, 10 0 khz ring wave ........................................................................ 29 15 appendi x ....................................................................................................................... .. 30 15.1 input cable bill of materi als ......................................................................................... 30 15.2 input cable assemb ly.................................................................................................. 30 15.3 heat sink assembly .................................................................................................... 31 16 revision history .............................................................................................................. 3 2
28-mar-2003 EPR-33 ? 45 w external adapter supply page 3 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com important no te: although the ep - 33 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.
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 4 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 1 introduction this document is an engineering report describing a 12 v, 45 w power supply, with intended application such as w lcd monitor adapters. this document contains the power supply specification, sch ematic, bill of materials, transformer documentation, printed circuit board layout, and performance data. figure 1 - ep-33 populated circuit board.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 5 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 2 power supply specification description symbol min typ max units comment input voltage v in 90 265 vac 3 wire frequency f line 47 50/60 64 hz no-load input power (230 vac) 0.3 w measured at 230 vac, 60 hz output output voltage 1 v out1 11.5 12.00 12.6 v 5% output ripple voltage 1 v ripple1 120 mv 20 mhz bandwidth output current 1 i out1 0.0 3.75 a total output power continuous output power p out 45 w peak output power p out_peak 45 w efficiency 83 % measured at p out (45 w), 25 c environmental conducted emi meets cispr22b / en55022b safety designed to meet iec950, ul1950 class ii surge 3 kv 1.2/50 s surge, iec 1000-4-5, 12 ? series impedance, differential and common mode surge 3 kv 100 khz ring wave, 500 a short circuit current, differential and common mode ambient temperature t amb 0 50 c free convection, sea level
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 6 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 3 schematic figure 2 ? ep-33 schematic.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 7 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 4 circuit description the schematic in figure 2 shows an off-line flyback converter using the top247y. the circuit is designed for 90 vac to 265 vac input and 12 v, 3.75 a output. 4.1 input emi filtering capacitor cx1 and the l1 leakage inductance filter differential-mode conducted emi. inductor l1 and cy1 filter common-mode conducted emi. inductor l4 damps line-cord resonance. 4.2 topswitch-gx primary rectifier bridge br1 and c1 provide a high voltage dc bus for the primary circuitry. c2 bypasses the high voltage dc rail. resistor r11 provides damping that reduces mid- frequency conducted emi. the dc rail is applied to the primary winding of t1. the other side of the transformer primary is driven by the integrated mosfet in u1. diode d1 and vr1 clamp leakage spikes generated when th e mosfet in u1 switches off. capacitor c3 reduces the operating temperature of vr1 by bypassing the leading edge of the primary leakage spike away from vr1. resistor r2 provides damping to reduce drain ringing. resistor r1 sets the low-line turn-on threshold to approximately 69 vac, and also sets the overvoltage shutdown level to approximately 320 vac. r3 sets the u1 current limit to approximately 55% of its nominal value. this limits the output power delivered during fault conditions. c4 bypasses the u1 control pin. c5 has 3 functions. it provides the energy required by u1 during startup, sets the auto-restart frequency during fault conditions, and also acts to roll off the gain of u1 as a function of frequency. r4 adds a zero to stabilize the power supply control loop. diode d2 and c6 provide rectified and filtered bias power for u2 and u1. 4.3 output rectification the output of t1 is rectified and filtered by d3, c7, and c8. inductor l2, c9, and c10 provide additional high frequency filtering. resistor r12 and c13 provide snubbing for d3. choosing the proper snubber values is important for low zero-load power consumption and for high frequency emi suppression. the snubber components were chosen so that the turn-on voltage spike at the d3 anode is slightly under-damped. increasing c13 and reducing r 12 will improve damping and high frequency emi, at the cost of higher zero-load power consumption. 4.4 output feedback resistors r8 and r9 divide down the supply output voltage and apply it to the reference pin of error amplifier u3. shunt regulator u3 drives optocoupler u2 through resistor r6 to provide feedback information to the u1 control pin. the optocoupler output also provides power to u1 during normal operating conditions. diode d4 and c11 apply drive to the optocoupler during supply startup to eliminate output voltage overshoot. diode d4 isolates c11 from the supply feedback loop after startup. resistor r5 discharges c11 when the supply is off.
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 8 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com components c5, c12, r4, r6, and r7 all play a role in compensating the power supply control loop. capacitor c5 rolls off the gain of u1 at relatively low frequency. resistor r4 provides a zero to cancel the phase shift of c5. resistor r6 sets the gain of the direct signal path from the supply output through u2 and u3. components c12 and r7 roll off the gain of u3.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 9 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 5 pcb layout figure 3 ? ep-33 printed circuit board layout (dimensions 0.001?).
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 10 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 6 bill of materials ep-33 rev. 10, 01/16/03 bill of materials item qty reference description p/n manufacturer 1 1 cx1 0.33 f, 250 v, x2 ecq-u2r334ml panasonic 2 1 c1 100 f, 400 v pag400vb101m16x30 united chemicon 3 1 c2 20 nf, 1 kv disc 5gas20 vishay 4 1 c3 4.7 nf, 1 kv disc 5gad47 vishay 5 3 c4, 10, 12 100 nf, 50 v c320c104k1r5ca kemet 6 1 c5 47 f, 16 v, 105 c eca-1chg470 panasonic 7 1 c6 1 f, 50 v, 105 c eca-1hhg010 panasonic 8 1 cy1 2.2 nf, y1 440ld22 cera-mite 9 2 c7, 8 680 f, 35 v, low esr kze35vb681m12.5x20 united chemicon 10 1 c9 100 f, 35 v, 105 c eca-1vhg101 panasonic 11 1 c11 10 f, 50 v, 105 c eca-1hhg100 panasonic 12 1 c13 470 pf, 100 v, x7r c315c471k1r5ca kemet 13 1 br1 bridge, 4 a, 600 v rs405m rectron 14 1 d1 1 a, 600 v, 75 ns uf4005 general semiconductor 15 1 d2, 4 diode, signal 1n4148 16 1 d3 20 a, 100 v, schottky mbr20100 general semiconductor 17 1 f1 fuse, 250 vac, 3.15 a 372-1315 wickman 18 1 l1 9.5 mh, 1.2 a elf-18n012a panasonic 19 1 l2 3.3 h, 5.5 a 6000-3r3m j. w. miller 20 1 r1 2 m ? , 5%, 1/2 w any 21 1 r2 68 ? , 5%, 1/2 w any 22 1 r3 16.5 k ? , 1%, 1/8 w any 23 1 r4 6.8 ? , 5%, 1/8 w any 24 1 r5 15 k ? , 5%, 1/8 w any 25 1 r6 1 k ? , 5%, 1/8 w any 26 1 r7 3.3 k ? , 5%, 1/8 w any 27 1 r8 10 k ? , 1%, 1/8 w any 28 1 r9 38.3 k ? , 1%, 1/8 w any 29 1 r10 8.2 m ? , 5%, 1/2 w any 30 1 r11 2.2 ? , 5%, 1/4 w any 31 1 r12 33 ? , 1/4 w, 5% any 32 1 t1 transformer, ee28 545 90 009 00 vogt sil6019 hical exl-529 rev. b excel electric 33 1 u1 top247y power integrations 34 1 u2 optocoupler isp817c isocom graded ctr 35 1 u3 shunt regulator, to-92 lm431acz national semiconductor 36 1 vr1 tvs, 200 v p6ke200 on semiconductor 37 1 rt1 thermistor, 5 ? , 3 a sck-053 thinking electronic 38 1 j1 assembly, ac receptacle see appendix 39 1 j2 assembly, output cable, 6?, 2 x 18 gauge, 2.5 mm female barrel connector, 14.3 mm x 28.6 mm molded ferrite filter 40 2 hs1, hs2 assembly, ep-33 heat sink see appendix 41 2 u1, d3 screw, 4-40 phil flat undercut zinc, 5/16? 42 2 u1, d3 nut, 4-40 kep zinc 43 1 d3 insulator, silicone 188858f00000 aavid/thermalloy to-220 44 1 d3 4-40 shoulder washer 3049 keystone electronics 0.031? shank 45 2 u1, d3 washer, 4-40 zinc 46 a/r jp1-3 bus wire, 22 awg 47 1 ep-33 pcb, rev. a
28-mar-2003 EPR-33 ? 45 w external adapter supply page 11 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7 transformer specification figure 4 ? ep-33 triple insulated transformer. 7.1 electrical specifications electrical strength 60 hz, 1 min, from pins 1-5 to pins 6-10 3000 vac creepage between pins 1-5 and pins 6-10 6 mm (min.) primary inductance pins 1-3, all other windings open, measured at 100 khz 521 h, 10% resonant frequency pins 1-3, all other windings open 1.2 mhz (min.) primary leakage inductance pins 1-3, with pins 6-10 shorted, measured at 100 khz 12 h (max.) 7.2 materials item description [1] core: nippon ceramic fee28/21/11, nc-2h material or equivalent. gap for al of 509 nh/t 2 [2] bobbin: 10 pin ei28, vertical mount, yih hwa yw-490 or equivalent [3] magnet wire: #25 awg double coated [4] magnet wire: #28 awg double coated [5] triple insulated wire: #25 awg [6] tape, 3m #1298 or equiv. 8.6 mm wide [7] varnish wdg #1 32t #25 awg 3 1 wdg #2 3t 3 x #28 awg 4 5 9,10 7,8 wdg #3 4t 6 x 25 awg triple insulated
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 12 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7.3 transformer build diagram figure 5 - ep-33 transformer build diagram. 7.4 transformer construction 1/2 primary start at pin 3. wind 16 turns of item [3] in one layer. basic insulation apply one layer of item [6] over completed winding layer. 1/2 primary wind remaining 16 turns, finish on pin 1. basic insulation apply one layer of item [6] for basic insulation. trifilar bias winding starting at pin 4, wind 3 trifilar turns of item [4]. spread turns evenly across bobbin. finish at pin 5. basic insulation use two layers of item [6] for basic insulation. hexafilar secondary winding start at pins 9 and 10. wind 4 hexafilar turns of item [5]. spread turns evenly across bobbin. finish on pins 7 and 8. outer wrap wrap windings with 3 layers of tape (item [6]). final assembly assemble and secure core halves. varnish impregnate (item [7]). 7.5 transformer sources for information on the vendors used to source the transformers used on this board, please visit the power integrations' web site at the url below and select ?engineering prototype boards?. http://www.powerint.com/componentsuppliers.htm pins side primary sec ondary 4 7,8 bias 3 5 1 9,10
28-mar-2003 EPR-33 ? 45 w external adapter supply page 13 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8 transformer spreadsheet power supply input vacmin volts 89 min input ac voltage vacmax volts 265 max input ac voltage fl hertz 50 ac main frequency tc msonds 2.11 bridge rectifier conduction time estimate z 0.49 loss allocation factor n % 80.0 efficiency estimate power supply outputs vox volts 12.00 output voltage iox amps 3.750 output current vb volts 12.00 bias voltage ib amps 0.006 bias current device variables device top247y/ f device name po watts 45.07 total output power vdrain volts 605 maximum drain voltage estimate (includes effect of leakage inductance) vds volts 3.9 device on-state drain to source voltage fs hertz 132000 device switching frequency krpkdp 0.40 ripple to peak current ratio ki 0.55 external current limit ratio ilimitext amps 1.84 device current limit external minimum ilimitmin amps 3.35 device current limit minimum ilimitmax amps 3.85 device current limit maximum ip amps 1.52 peak primary current irms amps 0.91 primary rms current dmax 0.56 maximum duty cycle power supply components selection cin ufarads 100.0 input filter capacitor vmin volts 83 minimum dc input voltage vmax volts 375 maximum dc input voltage vclo volts 150 clamp zener voltage pz watts 2.1 estimated primary zener clamp loss vdb volts 0.7 bias winding diode forward voltage drop pivb volts 60 bias rectifier maximum peak inverse voltage
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 14 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com power supply output parameters vdx volts 0.5 output winding diode forward voltage drop pivsx volts 59 output rectifier maximum peak inverse voltage ispx amps 11.95 peak secondary current isrmsx amps 6.43 secondary rms current iripplex amps 5.22 output capacitor rms ripple current transformer construction parameters core/bobbin ei28 core and bobbin type core manuf. generic core manufacturing bobbin manuf generic bobbin manufacturing lp uhenries 521 primary inductance np 32 primary winding number of turns nb 4.06 bias winding number of turns awg awg 24 primary wire gauge (rounded to next smaller standard awg value) warning! 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) cma cmils/a 444 primary winding current capacity vor volts 100.00 reflected output voltage bw mm 9.60 bobbin physical winding width m mm 0.0 safety margin width l 2.0 number of primary layers ae cm^2 0.86 core effective cross section area alg nh/t^2 509 gapped core effective inductance bm gauss 2871 maximum operating flux density bp gauss 4013 peak flux density bac gauss 574 ac flux density for core curves lg mm 0.19 gap length ll uhenries 3.9 estimated transformer primary leakage inductance lsec nhenries 10 estimated secondary trace inductance secondary parameters nsx 4.00 secondary number of turns rounded down nsx rounded to integer secondary number of turns rounded down vox volts auxiliary output voltage fo r rounded to integer nsx rounded up nsx rounded to next integer secondary number of turns rounded up vox volts auxiliary output voltage for rounded to next integer nsx awgsx range awg 15 - 19 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).
28-mar-2003 EPR-33 ? 45 w external adapter supply page 15 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9 performance data all measurements performed at room temperature, 60 hz input frequency. 9.1 efficiency ep-33 efficiency vs. i nput voltage, full load 79% 80% 81% 82% 83% 84% 85% 86% 87% 88% 80 100 120 140 160 180 200 220 240 260 280 input voltage (vac) efficiency (%) efficiency at supply output efficiency at cable end figure 6 - efficiency vs. input voltage, full load, room temperature, 60 hz.
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 16 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.2 no-load input power ep-33 no-load input power vs. line voltage 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 80 100 120 140 160 180 200 220 240 260 280 input voltage (vac) input power (w) figure 7 ? no-load input power vs. input line voltage, room temperature, 60 hz. 9.3 input power at 0.5 w load ep-33 input power vs. line voltage, 0.5 w load 0.75 0.8 0.85 0.9 0.95 1 80 100 120 140 160 180 200 220 240 260 280 input voltage (vac) input power (w) figure 8 ? input power vs. line voltage, 0.5 w load, room temperature.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 17 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.4 regulation 9.4.1 load ep-33 load regulation 95% 97% 99% 101% 103% 105% 01234 output load (a) regulation (% of nominal) 90 vac, output 90 vac, end of cable 115 vac, output 115 vac, end of cable 230 vac, output 230 vac, end of cable 265 vac, end of cable figure 9 - load regulation, room temperature. 9.4.2 line ep-33 line regulation, full load 95% 96% 97% 98% 99% 100% 101% 102% 103% 104% 105% 80 100 120 140 160 180 200 220 240 260 280 input voltage (vac) regulation (% of nominal) supply output end of cable figure 10 - line regulation, maximum load, room temperature.
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 18 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 10 thermal performance temperature ( c) item 90 vac 115 vac 230 vac 90 vac 115 vac 230 vac thermistor (rt1) 73 64 44 93 80 65 balun (l1) 48 42 32 78 67 58 bridge (br1) 72 61 49 97 85 71 topswitch-gx (u1) 60 53 52 91 84 78 clamp zener (vr1) 93 84 70 115 103 92 transformer (t1) 64 60 56 90 89 80 rectifier (d3) 83 80 73 107 102 98 ambient 25 25 26 50 50 49 figure 11 ? infrared thermograph of ep-33, 90 vac input, full load, 25 c ambient.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 19 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11 waveforms 11.1 drain voltage and current, normal operation figure 12 - 90 vac - upper: i drain , 0.5 a/div. lower: v drain , 100 v, 2 s/div. figure 13 - 265 vac, full load upper: i drain , 0.5 a/div. lower: v drain , 200 v, 2 s/div.
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 20 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.2 output voltage start-up profile figure 14 - start up profile at supply output, full load, 115 vac, 2 v, 10 ms/div. figure 15 - start up profile at supply output zero load, 115 vac. 2 v, 10 ms/div. figure 16 - start-up profile at supply output full load, 230 vac. 2 v, 10 ms/div. figure 17 - start up profile at supply output zero load, 230 vac, 2 v, 10 ms/div.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 21 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.3 drain voltage and cu rrent start-up profile figure 18 - 90 vac input and maximum load. upper: i drain , 0.5 a/div. lower: v drain , 100 v , 10 ms/div. figure 19 - 265 vac input and maximum load. upper: i drain , 0.5 a/div. lower: v drain , 200 v, 10 ms/div.
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 22 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.4 load transient response (75% to 100% load step) in the figures shown below, signal averaging was used to better enable viewing the load transient response. the oscilloscope was triggered using the load current step as a trigger source. since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response. figure 20 - 115 vac transient response. 75%-100%-75% load step. top: load current, 2 a/div. bottom: voltage at supply output 100 mv, 500 s/div. figure 21 - 230 vac transient response. 75%-100%-75% load step. top: load current, 2 a/div. bottom: voltage at supply output 100 mv, 1 ms/div. figure 22 - 115 vac transient response. 75%-100%-75% load step at end of cable. top: load current, 2 a/div. bottom: voltage at end of cable 100 mv, 500 s/div. figure 23 - 230 vac transient response 75%-100%-75% load step at end of cable. top: load current, 2 a/div. bottom: voltage at end of cable 100 mv, 1 ms/div.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 23 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5 output ripple measurements 11.5.1 ripple measurement technique for dc output ripple measurements, a modifi ed oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. details of the probe modification are provided in figure 24 and figure 25. the 5125ba probe adapter is affixed with two capacitors tied in parallel across the probe tip. the capacitors include one (1) 0.1 f/50 v ceramic type and one (1) 1.0 f/50 v aluminum electrolytic. the aluminum electrolytic type capacitor is polarized, so proper polarity across dc outputs must be maintained (see below). figure 24 - oscilloscope probe prepared for ripple measurement (end cap and ground lead removed). figure 25 - oscilloscope probe with probe master 5125ba bnc adapter (modified with wires for probe ground for ripple measurement and two parallel decoupling capacitors added). probe ground probe tip
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 24 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5.2 measurement results figure 26 - ripple, 90 vac, full load at end of cable. 2 ms, 50 mv/div. figure 27 - ripple, 115 vac, full load at end of cable. 2 ms, 50 mv/div. figure 28 - ripple, 230 vac, full load at end of cable. 2 ms, 50 mv/div.
28-mar-2003 EPR-33 ? 45 w external adapter supply page 25 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 12 control loop measurements 12.1 115 vac maximum load figure 29 - gain-phase plot, 115 vac, maximum steady state load. vertical scale: gain = 10 db/div., phase = 50 /div. crossover frequency ? 1.43 khz, phase margin - 62.6
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 26 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 12.2 230 vac maximum load figure 30 - gain-phase plot, 230 vac, maximum steady state load. vertical scale: gain = 10 db/div., phase = 50/div. crossover frequency - 1.86 khz, phase margin ? 64.7
28-mar-2003 EPR-33 ? 45 w external adapter supply page 27 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 13 conducted emi figure 31 - conducted emi, maximum steady state load, 115 vac, 60 hz, and en55022 b limits. figure 32 - conducted emi, maximum steady state load, 230 vac, 60 hz, and en55022 b limits. conducted emi was measured with output return connected to ground of lisn.
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 28 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 14 ac surge and 100 khz ring wave immunity four series of line transient tests were performed on the ep-33 to determine the level of immunity attainable for the basic board. testing was performed using a keytek emc-pro surge generator. the input voltage for the supply under test was 230 vac, and the supply was resistively loaded to the maximum continuous output power. the uut secondary return was hard wired to the surge generator earth connection to simulate use in an actual system. an led was used to monitor the presence of output voltage and to detect output interruptions. the test for each series was terminated upon non-destructive interruption of output voltage, arcing, or non-recoverable interruption of output voltage. a test failure was defined as a non-recoverable interruption of output voltage requiring supply repair or recycling of input ac voltage. 14.1 common mode surge, 1.2/50 sec surge voltage phase angle ( ) generator impedance number of strikes test result 1 kv 0 12 ? 10 pass 1 kv 90 12 ? 10 pass 1 kv 270 12 ? 10 pass 2 kv 0 12 ? 10 pass 2 kv 90 12 ? 10 pass 2 kv 270 12 ? 10 pass 2.5 kv 0 12 ? 10 pass 2.5 kv 90 12 ? 10 pass 2.5 kv 270 12 ? 10 pass 3 kv 0 12 ? 10 pass (1 interruption/10 strikes, supply recovered) 3 kv 90 12 ? 10 pass (1 interruption/10 strikes, supply recovered) 3 kv 270 12 ? 10 pass 14.2 differential mode surge, 1.2/50 sec surge voltage phase angle ( ) generator impedance number of strikes test result 1 kv 0 12 ? 10 pass 1 kv 90 12 ? 10 pass 1 kv 270 12 ? 10 pass 2 kv 0 12 ? 10 pass 2 kv 90 12 ? 10 pass 2 kv 270 12 ? 10 pass 3 kv 0 12 ? 10 pass 3 kv 90 12 ? 10 pass 3 kv 270 12 ? 10 pass 4 kv 0 12 ? 10 pass 4 kv 90 12 ? 10 pass 4 kv 270 12 ? 10 pass
28-mar-2003 EPR-33 ? 45 w external adapter supply page 29 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 14.3 common mode, 100 khz ring wave surge voltage (kv) phase angle ( ) short circuit current number of strikes test result 1 kv 0 500 a 10 pass 1 kv 90 500 a 10 pass 1 kv 270 500 a 10 pass 2 kv 0 500 a 10 pass 2 kv 90 500 a 10 pass 2 kv 270 500 a 10 pass 3 kv 0 500 a 10 pass 3 kv 90 500 a 10 pass 3 kv 270 500 a 10 pass 4 kv 0 500 a 1 pass (supply arcing, no power interruption) 14.4 differential mode, 100 khz ring wave surge voltage phase angle ( ) short circuit current number of strikes test result 1 kv 0 500 a 10 pass 1 kv 90 500 a 10 pass 1 kv 270 500 a 10 pass 2 kv 0 500 a 10 pass 2 kv 90 500 a 10 pass 2 kv 270 500 a 10 pass 3 kv 0 500 a 10 pass 3 kv 90 500 a 10 pass 3 kv 270 500 a 10 pass 4 kv 0 500 a 10 pass 4 kv 90 500 a 10 pass 4 kv 270 500 a 10 pass
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 30 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15 appendix 15.1 input cable bill of materials ep-33 input assy rev.2, 11/18/02 bill of materials item qty reference description p/n manufacturer 1 1 j1 input receptacle 701w-x2/02 qualtek 2 a/r wire, 18 awg, ul 1007, black, 0.08? dia 3 a/r wire, 18 awg, ul 1007, white, 0.08? dia. 4 a/r wire, 18 awg, ul 1007, grn/yel, 0.08? dia 5 1 l5 ferrite bead 2643006302 fair-rite 6 3 board-in terminal 02-07-2102 molex 7 a/r heat shrink fit221v-3/16 alpha 3/16?, ul vw-1 8 a/r heat shrink, fit221v-1/2 alpha 15.2 input cable assembly 1) cut 1 each 2? length items [2] and [3]. strip 0.25? each end 2) crimp 1 piece item [6] on one end of each wire. 3) cut one 12 ? piece item [4] 4) center 1 piece item [5] on item [4] cut length, wind 3 turns item [4] on item [5]. 5) trim one end item [4]. [5] assembly to 1.5?, other end to 4?. strip both ends 0.25?. 6) crimp one piece item [6] on 4? end of item [4], [5] assembly. 7) cut 3/4? length item [8], slide over item [4], [5] assembly so that it is centered on item [5], shrink in place. 8) solder remaining stripped ends of wires to receptacle [1] as shown, insulate each connection using 0.5? item [7]. [3] [1] [2] [5], [8] [6] (3 places) [4] [7] (3 places) l e n
28-mar-2003 EPR-33 ? 45 w external adapter supply page 31 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.3 heat sink assembly
EPR-33 ? 45 w external adapter supply 28-mar-2003 page 32 of 32 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 16 revision history date author revision description & changes 18-nov-2002 22-nov-2002 06-dec-02 rh rh rh 0.1 0.2 0.3 first draft second draft third draft 28-mar-03 rh 1.0 first release 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. ? 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 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 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. 17f-3, no. 510 chung hsiao e. rd., sec. 5, taipei, taiwan 110, r.o.c. phone: +886-2-2727-1221 fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com china 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 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 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 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 applications hotline world wide +1-408-414-9660 applications fax world wide +1-408-414-9760

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