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Design Example Report
Title 17W (25W peak) DVD Recorder Power Supply using TOP245P
Input: 90 - 265 VAC Output: 3.4V/2.55A, 5.1V/1.5A, 5.1Vsb/0.85A, Specification 12V/2.8A, 12Vsb/0.4A, -5.3V/0.3A, -5.3Vsb/20mA, -22Vsb/10mA, +33Vsb/2mA, 3.5V VFD/165mA Application Author Document Number Date Revision DVD Recorder Power Integrations Applications Department DER-18 March 30, 2004 1.0
Summary and Features This report describes a design for a DVD power supply, featuring the following: * No heatsinks * Switched Outputs for Low Standby consumption * Low cost/ Low parts count * No Y-cap * No X-cap * Meets EMI requirements
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 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
Table Of Contents
Introduction................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 Bill Of Materials .......................................................................................................... 8 Layout....................................................................................................................... 10 Transformer Specification......................................................................................... 11 Electrical Diagram........................................................................................................ 11 6.2 Electrical Specifications ........................................................................................ 12 6.3 Materials ............................................................................................................... 12 6.4 Transformer Build Diagram................................................................................... 13 6.4.1 WDG5/6 Copper Foil build diagram: .............................................................. 13 6.5 Transformer Construction ..................................................................................... 14 7 Transformer Spreadsheets....................................................................................... 15 8 Performance Data .................................................................................................... 19 8.1 Efficiency .............................................................................................................. 19 8.2 Cross Regulation .................................................................................................. 20 8.2.1 Nominal load.................................................................................................. 20 8.2.2 Peak Load (One output at a time).................................................................. 20 9 Thermal Performance............................................................................................... 23 10 Waveforms ............................................................................................................... 24 10.1 Drain Voltage and Current, Normal Operation .................................................. 24 10.2 Drain Voltage and Current Start-up Profile........................................................ 24 10.3 Output Start-up Profile...................................................................................... 25 10.4 Load Transient Response (Load Step).............................................................. 26 11 Output Ripple Measurements................................................................................... 27 11.1.1 Ripple Measurement Technique.................................................................... 27 11.1.2 Measurement Results.................................................................................... 28 12 Conducted EMI......................................................................................................... 32 12.1 EMI@230V........................................................................................................ 32 12.2 EMI@115V........................................................................................................ 33 13 Revision History ....................................................................................................... 34 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. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built. 1 2 3 4 5 6
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
1 Introduction
This document is an engineering report describing a prototype multiple output power supply utilizing a TOP245P. This power supply is designed for a DVD Recorder or similar application. This design is low cost and meets EMI with no X-cap, and no Y-cap. It meets thermal requirements with no heatsink in either primary or secondary side. 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. Component side (Top) and Solder side (Bottom).
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Output Voltage 3 Output Ripple Voltage 3 Output Current 3 Output Voltage 4 Output Ripple Voltage 4 Output Current 4 Output Voltage 5 Output Ripple Voltage 5 Output Current 5 Output Voltage 6 Output Ripple Voltage 6 Output Current 6 Output Voltage 7 Output Ripple Voltage 7 Output Current 7 Output Voltage 8 Output Ripple Voltage 8 Output Current 8 Output Voltage 8 Output Ripple Voltage 8 Output Current 8 Output Voltage 8 Output Ripple Voltage 8 Output Current 8 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Safety Ambient Temperature TAMB Symbol VIN fLINE Min 85 47 Typ Max 280 64 N/A 3.5 50 2.55 5.25 50 1.5 5.46 100 0.85 12.8 100 2.8 12.8 100 0.4 -5.0 50 0.3 -5.0 200 0.02 35 50 0.002 -18 50 0.010 3.85 50 0.165 17 25 74 Units VAC Hz W V mV A V mV A V mV A V mV A V mV A V mV A V mV A V mV A V mV A V mV A W W % Measured at POUT (17 W), o 25 C Comment
50/60
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 VOUT5 VRIPPLE5 IOUT5 VOUT6 VRIPPLE6 IOUT6 VOUT7 VRIPPLE7 IOUT7 VOUT8 VRIPPLE8 IOUT8 VOUT8 VRIPPLE8 IOUT8 VOUT8 VRIPPLE8 IOUT8 POUT POUT_PEAK
3.3
3.4
20 MHz Bandwidth
4.85
5.1
20 MHz Bandwidth Standby Output 20 MHz Bandwidth
4.94 .08 10.8 0 11.4 0.14 -5.5 0 -5.5 0 30 0.001 -28
5.1
12.0
20 MHz Bandwidth Standby Output 20 MHz Bandwidth
12.0
-5.3
20 MHz Bandwidth Standby Output 20 MHz Bandwidth Standby Output 20 MHz Bandwidth Standby Output 20 MHz Bandwidth Filament Power Floating Winding 20 MHz Bandwidth
-5.3
33
-22
3.15
3.5
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II o 25 C Free convection, sea level
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
3 Schematic
Figure 2 - Schematic (Primary Side)
Note: 1 - L9 was inserted on the actual board, it was not included in the original layout.
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
Figure 3 - Schematic (Secondary Side)
Note: 1- R30 was fitted in parallel with C23, it was not included in the original layout. 2- Snubber networks R31, R32, C31, & C32 were fitted in parallel with D8 and D12, and were not included in the original layout
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
Figure 4 - Schematic (Connector Side)
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
4 Bill Of Materials
Item Number 1 2 3 4 5 6 7 8 9 10 Qty. 1 1 1 1 1 1 1 4 3 4 Part Reference Value C1 C2 C3 C4 C5 C6 C7 C8 C11 C15 C23 C9 C25 C30 C10 C14 C18 C19 C12 C17 C20 C13 C16 C22 C24 C24a C27 CX CY* C21 C26 C28 C29 C31, C32 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 F1 J1 J2 J6 22uF/400V 22uF/400V 1nF/1KV 100nF 47uF 47uF 100uF 1uF 10uF 1000uF Description
Cap,Cer, 0.10 uF, 50V, Z5U, 20% Cap,Al Elect,47uF,16V,5mmX11.5mm,LXZ Series,NIPPON CHEMI-CON Cap,Al Elect,47uF,16V,5mmX11.5mm,LXZ Series,NIPPON CHEMI-CON Cap,Al Elect,100uF,50V,8mmX12mm,LXZ Series,NIPPON CHEMI-CON CAP 1uF 25V CERM CHIP X7R 0805 SMD Cap,Al Elect,12uF,50V,5mmX11.5mm,LXZ Series,NIPPON CHEMI-CON Cap,Al Elect,1000uF,16V,10mmX20mm,LXZ Series,NIPPON CHEMI-CON Cap,Al Elect,100uF,50V,8mmX11.5mm,KZE Series,NIPPON CHEMI-CON Cap,Al Elect,22uF,50V,5mmX11mm,KZE Series,NIPPON CHEMI-CON Cap,Al Elect,220uF,16V,6.3mmX11mm,LXZ Series,NIPPON CHEMI-CON Cap,Al Elect,220uF,10V,6.3mmX11mm,KZE Series,NIPPON CHEMI-CON CAP 0.1uF 50V CERM CHIP X7R 0805 SMD Cap,Al Elect,22uF,50V,5mmX11.5mm,LXZ Series,NIPPON CHEMI-CON Cap,Cer, 470pF, 1kV, Z5U, 20% Rectifier GPP 600V 1A DO-41 Rectifier GPP 1000V 1A DO-41 Diode Fast Switch 250V 500MW DO35 Rectifier Ultrafast 200V, 1A, D0-201AD RECT,DL4148, PASSIVATED 500mW SMD MELF Rectifier Schottky 3A 40V DO-201AD Rectifier Schottky 5A 30V DO-201AD Rectifier Ultrafast 50V, 1A, D0-41 Rectifier Fast Rec 200V 1A DO-41 Rectifier Schottky 1A 40V DO-41 FUSE T-LAG 2A,250V Slo-Blo IEC SHORT TR5 Terminal,1Pin,18AWG
11 12
3 8
100uF 22uF
13 14 15 16 16a 17 18 19 20 21 22 23 23a 24 25 26 27 28 29
1 1 1 1 2 4 1 1 1 1 3 1 1 1 1 1 1 2 1
220uF 220uF 100nF 22uF 470pf 1N4005 1N4007GP BAV20 BAV21 UF5402 DL4148 SB340CT SB530CT UF4001 1N4935 1N5819 2A TERM_1Pin CON10
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DER-18
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 63a 64 65 66 66a 66b 67 68 69 70 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
DVD Recorder Supply - TOP245P
J7 J8 J9 L1 L2 L3 L4 L6 L8 L9 Q1 Q2 Q3 Q4 Q5 Q6 R1 R2 R3 R4 R5 R6 R7 R21 R8 R9 R10 R15 R11 R12 R13 R14 R23 R16 R18 R19 R20 R22 R24 R25 R26 R27 R28 R29 R30 R31 R32 T1 U1 U2 U3 CON12 CON4 CON4 10mH / 0.8A 3.3uH F.B. 680uH Si2302ADS Si2302ADS MMST3906-7 Si2312DS Si2312DS MMBT3904 200k 100R 2M2 6R8 220R 47R 10k 3M3 2M2 220 180R 2M2 10k 11k 1R 0 1k2 22k 4k7 10k 3k0 1K0 750R 10R 1M0 4R7 20R EER28L TOP245P PC817X1 TL431
March 30, 2004
Inductor,3.3uH,2.66A Bead,Ferrite,2.0 uH,Axial COIL 680.uH MOLDED SHIELDED
TRANSISTOR,2N3906, PNP 40V SOT-323
Res, 200K, 1/4W, 5%, Carbon Film Res, 100, 1/4W, 5%, Carbon Film Res, 2.2M, 1/2W, 5%, Carbon Film Res, 6.8, 1/4W, 5%, Carbon Film Res, 220, 1/4W, 5%, Carbon Film Res, 47, 1/4W, 5%, Carbon Film Res,10K 1/10W 1% 0805 SMD Res, 3.3M, 1/4W, 5%, Carbon Film Res,2.2M 1/8W 5% 1206 SMD Res, 220R, 1/4W, 5%, Carbon Film Res, 180, 1/4W, 5%, Carbon Film Res, 2.2M, 1/4W, 5%, Carbon Film Res, 10K, 1/4W, 5%, Carbon Film Res, 11K, 1/4W, 5%, Carbon Film Res, 1 ,1/4W, 5%, Metal Film Res,XXX 1/10W 1% 0805 SMD Res,1.2K 1/10W 5% 0805 SMD Res, 22K, 1/4W, 5%, Carbon Film Res, 4.7K, 1/4W, 5%, Carbon Film Res, 10K, 1/8W, 5%, Carbon Film Res, 3.0K, 1/4W, 5%, Carbon Film Res, 1.0K, 1/4W, 5%, Carbon Film Res, 750, 1/2W, 5%, Carbon Film Res, 10, 1/4W, 5%, Carbon Film Res,1.0M 1/10W 5% 0805 SMD Res, 4R7, 1/8W, 5%, Carbon Film Res, 20R, 1/8W, 5%, Carbon Film Custom (See Spec) TOPSwitch IC,PC817A1,PHOTOCOUPLER TRAN OUT CTR 80-160% 4-DIP Shunt regulator 1%
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
5 Layout
Figure 5: PCB Layout. Dimension: 7.3 in X 4 in. Note: Some components were added and are not shown above (see schematic note).
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
6 Transformer Specification
6.1 Electrical Diagram
1
WDG2 56T 29 AWG
16
WDG8 11T 33 AWG
15 5 7
WDG3 8T 30 AWG X4 WDG7 4T 26 AWG
14
WDG6 1T CU FOIL
6 nc
WDG1 16T 30 AWG X2
12
WDG5 2T CU FOIL
1
13
WDG9 3T 26 AWG
11
WDG10 9T 33 AWG
10 8
WDG11 2T 33 AWG
9 nc
WDG4 9T 29 AWG X4
13
Figure 6 -Transformer Electrical Diagram
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
6.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-7 to Pins 8-16 Pins 1-5, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-5, all other windings open Pins 1-5, with Pins 8-16 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 550 H, +10% 750 kHz (Min.) 40 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
6.3
Materials
Description Core: EER28L Bobbin: BEER28L, VERTICAL 16-PINS Magnet Wire: 30 AWG Magnet Wire: 29 AWG Magnet Wire: 33 AWG Magnet Wire: 26 AWG Tape: Margin 6 mm Tape, Tape: 3M 1298 Polyester Film, 10.5mm wide Tape, Tape: 3M 1298 Polyester Film, 22mm wide Tape, Tape: 3M 1298 Polyester Film, 14mm wide Copper Foil: 1mil x 9.5mm wide x 190 mm long Varnish
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12]
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
6.4
Transformer Build Diagram
CORE
2 tape
CORE
6mm margin tape
9 8 10 11 11 13 15 16 14 15 12 13
WDG11 2T 33 AWG WDG10 9T 33 AWG WDG9 3T 26 AWG WDG8 11T 33 AWG WDG7 4T 26 AWG
1 tape
1 tape
13 WDG5/6 14 3T Cu FOIL
WDG4 9T 29 AWG X3 WDG3 8T 30 AWG X4 WDG2 56T 29 AWG WDG1 16T 30 AWG X2
4 tape
7 6 1
2 tape
1 tape
5
2 tape
1
Figure 7 - Transformer Build Diagram.
6.4.1 WDG5/6 Copper Foil build diagram:
Cu Foil 1mil; 9.5mm W x 190mm 1-layer tape folded
65mm
125mm
26 AWG X2
Figure 8 - Copper Foil Build Diagram.
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
6.5
Transformer Construction
Bobbin Preparation Margin WGD1: Shield Basic Insulation WGD2: Primary st (1 -layer) Basic Insulation WGD2: Primary nd (2 -layer) Basic Insulation WGD3: Bias Reinforced Insulation Margin WGD4: Bias Basic Insulation WGD5/6: 3V/5V WGD7: 12V WGD8: 33V Basic Insulation WGD9: - 5V WGD10: - 22V WGD11: 3V VFD Outer Wrap Core Preparation Final Assembly
Pull Pins 2, 3 & 4 on bobbin to provide polarization. Place the bobbin with pins oriented on the right hand side. Apply 6 mm wide margin tape on both sides of the bobbin. Match height of primary windings. Start at Pin 1. Wind 16 bifilar turns of 30 AWG wire in 1 layer. Cut end leads floating. Use two layers of 10.5 mm tape for basic insulation. st Start at Pin 5. Wind 30 turns of 29 AWG wire for the 1 layer. Put one layer of 10.5 mm tape for basic insulation nd Continue winding 26 turns for the 2 layer. Finish on Pin 1. Put two layers of 10.5 mm tape for basic insulation Start at Pin 6. Wind 8 quadfilar turns of 30 AWG wire in 1 layer. Finish on Pin 7. Put 4 layers of 22 mm tape for reinforced insulation Apply 6 mm wide margin tape on both sides of the bobbin. Match height of secondary windings. Start at Pin 16 temporarily. Wind 9 quadfilar turns of 29 AWG wire in 1 layer. Finish on Pin 13. Cut start-leads floating. Put one layer of 10.5mm tape for basic insulation Use prepared cu foil shown in Figure 7. Start at pin 14, wind 1 turn, terminate at pin 12,continue to wind two turns. Finish at pin 13. Secure end with 10.5 mm tape. Start at Pin 15. Wind 4 turns of 26 AWG wire in 1 layer. Spread evenly across the bobbin. Finish on Pin 14. Start at Pin 16. Wind 11 turns of 33 AWG wire in 1 layer. Spread evenly across the bobbin. Finish on Pin 15. Put one layer of 10.5 mm tape for basic insulation Start at Pin 13. Wind 3 turns of 26 AWG wire in 1 layer. Spread evenly across the bobbin. Finish on Pin 11. Start at Pin 11. Wind 9 turns of 33 AWG wire in 1 layer. Spread evenly across the bobbin. Finish on Pin 10. Start at Pin 8. Wind 2 turns of 33 AWG wire in 1 layer. Spread evenly across the bobbin. Finish on Pin 9. Wrap windings with 2 layers of 22 mm tape Glue core halves together. Varnish impregnate
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
7 Transformer Spreadsheets
ACDC_TOPGX_Rev1.5_081203 Copyright Power Integrations Inc. 2003
INPUT INFO OUTP UNIT UT
ENTER APPLICATION VARIABLES VACMIN VACMAX fL VO PO n Z VB tC CIN
TOP_GX_081203.xls: TOPSwitch-GX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage
90 280 50 5 25 0.75 0.75 15 3 44
Volts Volts Hertz Volts Watts
Efficiency Estimate Loss Allocation Factor Volts Bias Voltage mSeco Bridge Rectifier Conduction Time nds Estimate uFarad Input Filter Capacitor s
ENTER TOPSWITCH-GX VARIABLES
TOP-GX Chosen Device KI
TOP2 45P
ILIMITMIN ILIMITMAX Frequency - (F)=132kHz, (H)=66kHz fS fSmin fSmax VOR VDS VD VDB KP
Univer 115 Doubled/230V sal TOP24 Power 22W 30W Out 5P 1 External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) 1.023 Amps Use 1% resistor in setting external ILIMIT 1.177 Amps Use 1% resistor in setting external ILIMIT F Full (F) frequency option - 132kHz 13200 Hertz 0 12400 Hertz 0 14000 Hertz 0 Volts Volts Volts Volts TOPSwitch-GX Switching Frequency: Choose between 132 kHz and 66 kHz TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX Maximum Switching Frequency Reflected Output Voltage TOPSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.4 < KRP < 1.0 : 1.0< KDP<6.0)
13200 0
103 10 0.5 0.7 0.50
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ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type Core Bobbin
DVD Recorder Supply - TOP245P
March 30, 2004
EER2 8L EER28 L EER28 L_BOB BIN 0.814 7.55 2520 21.5 P/N: P/N: PC40EER28L-Z BEER-28L-1112CPH
AE LE AL BW M L NS DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS TRANSFORMER PRIMARY DESIGN PARAMETERS LP NP NB ALG BM BP BAC ur LG BWE OD INS DIA
21.5 6 2.1 3
cm^2 cm nH/T^2 mm mm
Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns
75 Volts 396 Volts
Minimum DC Input Voltage Maximum DC Input Voltage
0.61 0.45 0.97 0.48 0.58
Amps Amps Amps Amps
Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current
Primary Winding Number of Turns Bias Winding Number of Turns Gapped Core Effective Inductance Maximum Flux Density at PO, VMIN (BM<3000) 1846 Gauss Peak Flux Density (BP<4200) 380 Gauss AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) 1860 Relative Permeability of Ungapped Core 0.41 mm Gap Length (Lg > 0.1 mm) 19.95 mm Effective Bobbin Width 0.36 mm Maximum Primary Wire Diameter including insulation 0.06 mm Estimated Total Insulation Thickness (= 2 * film thickness) 0.30 mm Bare conductor diameter
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717 uHenri es 56 9 227 nH/T^2 1518 Gauss
Primary Inductance
Page 16 of 35
DER-18
AWG CM CMA
DVD Recorder Supply - TOP245P
29 AWG
March 30, 2004
Primary Wire Gauge (Rounded to next smaller standard AWG value) 128 Cmils Bare conductor effective area in circular mils 221 Cmils/ Primary Winding Current Capacity (200 Amp < CMA < 500)
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP ISRMS IO IRIPPLE CMS AWGS DIAS ODS INSS
18.13 8.60 5.00 7.00
Amps Amps Amps Amps
Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness
1721 Cmils 17 AWG 1.15 mm 3.17 mm 1.01 mm
VOLTAGE STRESS PARAMETERS VDRAIN PIVS PIVB
632 Volts 26 Volts 75 Volts
Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1
3.4 2.550 0.5
Volts Amps 8.67 Watts Volts 2.13 4.388 Amps 3.57 Amps 18 Volts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse
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DVD Recorder Supply - TOP245P
Voltage
March 30, 2004
CMS1 AWGS1 DIAS1 ODS1
878 Cmils 20 AWG 0.81 mm 4.47 mm
Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2
12.2 0.850 1.2
Volts Amps 10.37 Watts Volts 7.31 1.463 Amps 1.19 Amps 64 Volts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
CMS2 AWGS2 DIAS2 ODS2
293 Cmils 25 AWG 0.46 mm 1.30 mm
3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3
33.0 0.002 1.0
Volts Amps 0.07 Watts Volts 18.55 0.003 Amps 0.00 Amps 164 Volts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire !!!!!!!!!! Warning: total output power not equal to PO (PO= 25 W)
CMS3 AWGS3 DIAS3 ODS3
1 Cmils 51 AWG 0.02 mm 0.51 mm
Total power
19.10 Watts 6
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DVD Recorder Supply - TOP245P
March 30, 2004
8 Performance Data
All measurements performed at room temperature, 60 Hz input frequency, unless otherwise specified. 8.1 Efficiency
Load Condition: 3.3Vsb/2A; 5Vsw/0.4A; 5Vsb/0.4A; 12Vsw/0.3A, 12Vsb/0.1A; 5Vsw/01.A; -5Vsb/240 ohms, -22Vsb/11K; +33Vsb/16Kohms; 3.3V VFD/20 ohms
Efficiency (Nominal Load) 80.00 75.00 Efficiency (%) 70.00 Efficiency (Nominal Load) 65.00 60.00 55.00 50.00 90 120 150 180 Input (VAC) 210 240 270
Figure 9- Efficiency vs. Input Voltage, Room Temperature, 60 Hz. Efficiency at 115Vac and 230Vac are 76.3% and 76.5% respectively.
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DVD Recorder Supply - TOP245P
March 30, 2004
8.2
Cross Regulation
8.2.1 Nominal load
Load Condition: 3.3Vsb/2A; 5Vsw/0.4A; 5Vsb/0.4A; 12Vsw/0.3A, 12Vsb/0.1A; -5Vsw/0.08A; -5Vsb/240 ohms, -22Vsb/11K; +33Vsb/16Kohms; 3.3V VFD/20 ohms
Vout (VDC)
3.3Vsb 5Vsw/ 5Vsb/ 12Vsw 12Vsb -5Vsw -5Vsb -22Vsb +33Vsb 3.3V VFD
Load (A)
2A 0.4A 0.4A 0.3A 0.1A 0.08A 240 ohms 11K 16Kohms 20 ohms
@115V
3.25 V 5.27 5.28 12.50 12.51 -5.08 -5.17 -22.81 33.07 3.24
@230V
3.25 5.27 5.28 12.46 12.47 -5.15 -5.15 -22.71 32.94 3.24
Figure 9 -Nominal load at Room Temperature.
8.2.2 Peak Load (One output at a time) At 115V Vout
3.3Vs b 5Vsw/ 5Vsb/ 12Vsw 12Vsb -5Vsw -5Vsb 22Vsb +33Vs b 3.3V VFD
Iout
2.51Apk
Vout
(measured)
Iout
2A 1.2Apk
Vout
(measured)
Iout
2A
Vout
(measured)
Iout
2A
Vout
(measured)
3.15 V 5.27 5.28 12.5 12.51 -5.22 -5.22 -22.92 33.26 3.25
3.27 V 5.22 5.28 12.71 12.72 -5.37 -5.37 -23.5 34.05 3.31
3.23 V 5.27 5.28 12.52 12.53 -5.21 -5.21 -22.89 33.23 3.26
3.21 V 5.27 5.28 12.2 12.26 -5.41 -5.41 -23.58 34.05 3.26
0.4A 0.4A 0.3A 0.1A 0.08A 240 11K 16K 20
0.4A
0.55Apk
0.4A 0.3A 0.1A 0.08A 240 11K 16K 20
0.4A 0.4A
1.2Apk
0.3A 0.1A 0.08A 240 11K 16K 20
0.1A 0.08A 240 11K 16K 20
Page 20 of 35
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DER-18 Continuation (115V)
DVD Recorder Supply - TOP245P
March 30, 2004
Vout
3.3Vs b 5Vsw/ 5Vsb/ 12Vsw 12Vsb -5Vsw -5Vsb 22Vsb +33Vs b 3.3V VFD
Iout
2A
Vout
(measured)
Iout
2A
Vout
(measured)
3.22 V 5.27 5.28 12.38 12.51 V -5.23 -5.24 -22.96 33.29 3.25
3.22 V 5.29 5.28 12.46 12.47 -5.0 V -5.0 -22.61 33.0 3.24
0.4A 0.4A 0.3A 0.4Apk 0.08A 240 11K 16K 20
0.4A 0.4A 0.3A 0.1A 0.12Apk 240 11K 16K 20
At 230V Vout
3.3Vs b 5Vsw/ 5Vsb/ 12Vsw 12Vsb -5Vsw -5Vsb 22Vsb +33Vs b 3.3V VFD
Iout
2.51Apk
Vout
(measured)
Iout
2A 1.2Apk
Vout
(measured)
Iout
2A
Vout
(measured)
Iout
2A
Vout
(measured)
3.19 V 5.27 5.28 12.48 12.49 -5.18 -5.18 -22.81 33.08 3.31
3.29 V 5.22 5.28 12.64 12.66 -5.29 -5.29 -23.22 33.67 3.30
3.25 V 5.27 5.28 12.49 12.5 -5.17 -5.17 -22.77 33.05 3.26
3.24 V 5.27 5.28 12.22 12.29 -5.3 -5.3 -23.2 33.55 3.25
0.4A 0.4A 0.3A 0.1A 0.08A 240 11K 16K 20
0.4A
0.55Apk
0.4A 0.3A 0.1A 0.08A 240 11K 16K 20
0.4A 0.4A
1.2Apk
0.3A 0.1A 0.08A 240 11K 16K 20
0.1A 0.08A 240 11K 16K 20
Page 21 of 35
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DER-18 Continuation (230V)
DVD Recorder Supply - TOP245P
March 30, 2004
Vout
3.3Vs b 5Vsw/ 5Vsb/ 12Vsw 12Vsb -5Vsw -5Vsb 22Vsb +33Vs b 3.3V VFD
Iout
2A
Vout
(measured)
Iout
2A
Vout
(measured)
3.25 V 5.27 5.28 12.36 12.37 -5.18 -5.18 -22.78 33.04 3.25
3.25 5.27 5.28 12.44 12.45 -4.99 -4.99 -22.53 32.86 3.25
0.4A 0.4A 0.3A 0.4Apk 0.08A 240 11K 16K 20
0.4A 0.4A 0.3A 0.1A 0.12Apk 240 11K 16K 20
Page 22 of 35
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
9 Thermal Performance
Open chassis measurement. The temperature stabilized after 1 hour of continuous nominal load operation without airflow.
Load Condition: 3.3Vsb/2A; 5Vsw/0.4A; 5Vsb/0.4A; 12Vsw/0.3A, 12Vsb/0.1A; -5Vsw/0.08A; -5Vsb/240 ohms, -22Vsb/11K; +33Vsb/16Kohms; 3.3V VFD/20 ohms
Temperature (C) Item Ambient TOP245P (U1) Transformer (T1) 3V Rectifier (D13) 5V Rectifier (D12) 12V Rectifier (D8) 90VAC 25 61 43 71 58 54 265 VAC 25 68 41 70 59 58
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
10 Waveforms
10.1 Drain Voltage and Current, Normal Operation
Figure 10 - 115 VAC, Nominal Load. Upper: VDRAIN, 200 V, 2 s / div Lower: IDRAIN, 0.5 A / div
Figure 10a - 230 VAC, Nominal Load Upper: VDRAIN, 200 V / div,2 s / div Lower: IDRAIN, 0.5 A / div
10.2 Drain Voltage and Current Start-up Profile
Figure 11 - 90 VAC Input and Maximum Load. Upper: IDRAIN, VDRAIN, 100 V & 5 ms / div. Lower: 1A / div.
Figure 12 - 265 VAC Input and Maximum Load. Upper: VDRAIN, 200 V & 5 ms / div. Lower: IDRAIN, 1 A / div.
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
10.3 Output Start-up Profile
Figure 13 - 115 VAC Input and Nominal Load. 5Vsb/12Vsb/33Vsb, 5 V & 20 ms / div.
Figure 14 - 230 VAC Input and Nominal Load. 5Vsb/12Vsb/33Vsb, 5 V & 20 ms / div.
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
10.4 Load Transient Response (Load Step) In the figures shown below, signal averaging was used to enable better viewing of 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.
At 5Vsb output
Figure 15 - Transient Response, 90 VAC, 1.2A1.7A Load Step. Top: Output Voltage 1V, 1 ms / div Bottom: Load Current 2 A/div
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
11 Output Ripple Measurements
11.1.1 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 16 and Figure 17. 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 16 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 17 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
11.1.2 Measurement Results Peak Load (One output at a time)
Figure 18 - 3.3Vsw Ripple, 115 VAC, Peak Load. 5 ms, 20 mV / div
Figure 19 - 3.3 Vsw Ripple, 230 VAC, Peak Load. 5 ms, 20 mV / div
Figure 20 - 5Vsw Ripple, 115 VAC, Peak Load. 5 ms, 20 mV /div
Figure 21 - 5Vsw Ripple, 230 VAC, Peak Load. 5 ms, 20 mV /div
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
Figure 22 - 5Vsb Ripple, 115 VAC, Peak Load. 5 ms, 20 mV / div
Figure 23 - 5 Vsb Ripple, 230 VAC, Full Load. 5 ms, 20 mV / div
Figure 24 - 12Vsw Ripple, 115 VAC, Peak Load. 5 ms, 50 mV /div
Figure 25 - 12Vsw Ripple, 230 VAC, Peak Load. 5 ms, 50 mV /div
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
Figure 26 - 12Vsb Ripple, 115 VAC, Peak Load. 5 ms, 50 mV / div
Figure 27 - 12 Vsb Ripple, 230 VAC, Peak Load. 5 ms, 50 mV / div
Figure 28 - -5Vsw Ripple, 115 VAC, Peak Load. 5 ms, 20 mV /div
Figure 29 - -5Vsw Ripple, 230 VAC, Peak Load. 5 ms, 20 mV /div
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
Figure 30 - -5Vsb Ripple, 115 VAC, Peak Load. 5 ms, 50 mV / div
Figure 31 - -5 Vsb Ripple, 230 VAC, Peak Load. 5 ms, 50 mV / div
Figure 32 - -22Vsb Ripple, 115 VAC, Peak Load. 5 ms, 20 mV /div
Figure 33 - -22Vsb Ripple, 230 VAC, Peak Load. 5 ms, 20 mV /div
Figure 34 - 33Vsb Ripple, 115 VAC, Peak Load. 5 ms, 50 mV / div
Figure 35 - 33 Vsb Ripple, 230 VAC, Peak Load. 5 ms, 50 mV / div
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
12 Conducted EMI
EMI was tested at room temperature, at 115 VAC & 230 VAC input, with a resistor load on each output as follows; 3.3V / 1.6 ohms; 5V / 7 ohms; 12V / 31 ohms; -5V / 240 ohms; -22V / 11K ohms; 33V / 16K ohms; VFD / 20 ohms. All plots are shown with output common connected to the ground of the LISN, to show worst case results. 12.1 EMI@230V
Figure 36 - Conducted EMI, Maximum Steady State Load, LINE: 230 VAC, 60 Hz, and EN55022 B Limits, with output grounded to LISTN
Figure 37 - Conducted EMI, Maximum Steady State Load, NEUTRAL 230 VAC, 60 Hz, and EN55022 B Limits, with output grounded to LISTN
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
12.2 EMI@115V
Figure 38 - Conducted EMI, Maximum Steady State Load, LINE: 115 VAC, 60 Hz, and EN55022 B Limits, , with output grounded to LISTN
Figure 39 - Conducted EMI, Maximum Steady State Load, NEUTRAL 115 VAC, 60 Hz, and EN55022 B Limits, , with output grounded to LISTN
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
13 Revision History
Date Author March 30, 2004 ME Revision 1.0 Description & changes First Release Reviewed VC /AM
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DER-18
DVD Recorder Supply - TOP245P
March 30, 2004
For the latest updates, visit our Web site: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein, nor does it convey any license under its patent rights or the rights of others. 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. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2003, Power Integrations.
WORLD HEADQUARTERS Power Integrations 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 AMERICAS Power Integrations, Inc. 4335 South Lee Street, Suite G, Buford, GA 30518, USA Phone: +1-678-714-6033 Fax: +1-678-714-6012 e-mail: usasales@powerint.com
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