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Design Example Report
Title Specification Application Author Document Number Date Revision
Summary
This report details the design of a primary-side regulated isolated Flyback converter.
24 W Primary-side Regulated Flyback Power Supply using TOP245Y Input: 90 - 265 VAC Output: 8V / 3A LED Lighting Power Integrations Applications Department DER-100 December 7, 2005 2.0
* * * *
Provides 8 V @ 3 A Typical Efficiency 80 %. Primary-side regulation Low parts count
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
DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
Table Of Contents
1 2 3 4 5 6 7 Introduction .......................................................................................................................... 3 Power Supply Specification.................................................................................................. 4 Schematic ............................................................................................................................ 5 Bill Of Materials.................................................................................................................... 6 Transformer Specification .................................................................................................... 7 Transformer Design Spread Sheet .................................................................................... 11 Performance Data.............................................................................................................. 15 7.1 Line and Load Regulation ........................................................................................... 15 7.2 Efficiency .................................................................................................................... 15 8 Waveforms......................................................................................................................... 16 8.1 Output Voltage Startup ............................................................................................... 16 8.2 Drain Voltage / Current ............................................................................................... 16 8.3 Output Ripple Measurements ..................................................................................... 17 8.3.1 Ripple Measurement Technique .......................................................................... 17 8.3.2 Output Voltage Ripple.......................................................................................... 18 9 EMI Tests........................................................................................................................... 19 10 Revision History.............................................................................................................. 20
Important Notes: 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 isolated source to provide power 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.
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
1 Introduction
This document is an engineering report giving performance characteristics of a 24 W Flyback converter - 8 V @ 3 A. This design uses TOPSwitch-GX - an integrated IC comprising a high voltage MOSFET, and PWM controller. This document contains power supply specification, schematic, bill-of-materials, transformer documentation, printed circuit layout, and performance data. A photo of the power supply prototype is shown in Figure 1.
Figure 1 - Power Supply Prototype - Top View
Page 3 of 22
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
2 Power Supply Specification
Description Input Voltage Outputs Output Voltage Output Ripple Voltage Output Current Continuous Output Power Conducted EMI Margin Efficiency Ambient Temperature TAMB 0 Symbol VIN VOUT VRIPPLE IOUT POUT 10 80 50 Min 90 8 200 3 24 Typ Max 265 Units Vac V mV A W Comment
20 MHz Bandwidth Continuous
dB %
o
EN550022 B, FCC B At full load Free convection, Sea level
C
Table 1 - Power Supply Specification
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
3 Schematic
C1 D5 D1
DF06S
600 V
3 + 1
2.2 nF T1 10
6
43CTQ100S
+8V @ 3A
C8
1200uF
35 V
C3
100uF
400V
1
C5
1 nF
1 kV
3
C7
1200uF
35 V
2
VR1
P6KE200A
R2
100
1%
D6
5 4
RTN
4
ES1D
EI25
T2
10 mH
D4
1N4007GP
VR2
ZMM5243B-7
13 V
R3
2M
D L C SXF
R8
160
C10
100 nF
275 VAC
U1
TOP245Y
CONTROL
C14 R6
8.2 ohm 1.0 uF
50 V
F1
3.15A
RT1
10 ohms
R7
11k
C12
100 nF
50 V
C13
47 uF
10 V
t
L N
1%
90 - 265 VAC 50/60Hz
Figure 2 - 24 W, Power Supply Schematic
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
4 Bill Of Materials
Item QTY Part Reference 1 1 C1 2 1 C3 3 1 C5 4 2 C7 C8 5 1 C10 6 1 C12 7 1 C13 8 1 C14 9 1 D1 10 1 D4 11 1 D5 12 1 D6 13 1 F1 14 1 R2 15 1 R3 16 1 R6 17 1 R7 18 1 R8 19 1 RT1 20 1 T1 21 1 T2 22 1 U1 23 1 VR1 24 1 VR2 Description
2.2nF, Ceramic, Y1 100uF, 400 V, Electrolytic, High Ripple 1nF, 1 kV, Disc Ceramic 100uF, 35 V, Electrolytic, Low ESR 100nF, 275 VAC, Film, X2 100nF, 50 V, Ceramic, X7R, 0805 47uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) 1.0uF, 50 V, Ceramic, Z5U 600 V, 1 A, Bridge Rectifier, SMD, DFS 1000 V, 1 A, Rectifier, DO-41 100 V, 43 A, Dual Schottky, (D2-PAK) 100 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC 3.15 A, 250V, Slow, TR5 100 R, 1%, 1/4 W, Metal Film 2 M, 5%, 1/4 W, Metal Film, 1206 8.2 R, 5%, 1/8 W, Metal Film, 0805 15 k, 1%, 1/8 W, Metal Film, 0805 160 R, 5%, 1/4 W, Metal Film, 1206 NTC Thermistor, 5 Ohms, 2.8 A Bobbin, EI25, Horizontal, 10 pins 10 mH, 1A, Common Mode Choke TOPSwitch-GX, TOP245Y, TO-263-7C 200 V, 5 W, 5%, DO204AC (DO-15) 13 V, 5%, 500 mW, DO-213AA (MELF)
Mfg Vishay Panasonic NIC Components Corp Panasonic Panasonic Panasonic United Chemi-Con Panasonic Vishay Vishay International Rectifier Vishay Wickman Yageo Panasonic Panasonic Panasonic Panasonic Thermometrics Epcos Tokin Power Integrations Vishay Diodes Inc
Mfg Part Number 440LD22 NCD102K1KVY5F ECQ-U2A104ML ECU-V1H221KBN KME10VB22RM5X11LL ECU-S1H105MEB 1N4007GP 43CTQ100S ES1D 3,721,500,041 MFR-25FBF-102R ERJ-8GEYJ205V ERJ-6GEYJ8R2V ERJ-6ENF1502V ERJ-8ENF1620V CL160 SC-01-E100G TOP245Y P6KE200A ZMM5243B-7
Table 2 - Bill of Materials
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
5 Transformer Specification
Transformer Construction
Electrical Diagram
Winding Order
Core Information Core Type Core Material Estimated Gap length, mm Gapped Effective Inductance, nH/t^2 Primary Inductance, uH Bobbin Information (Manual Input) Bobbin Reference Bobbin Orientation
EI25 NC-2H or Equivalent 0.362 133 686
Generic, 5 pri. + 5 sec. Vertical
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Page 7 of 22
DER-100
24W Flyback Power Supply - TOP245
5 5 0.0 0.0
December 7, 2005
Number of Primary pins Number of Secondary pins Margin on Bottom, mm Margin on Top, mm Primary Winding (Manual Input) Parameter Number of Turns Wire Size, AWG Filar Layers Start Pin(s) Termination Pin(s) BIAS Winding Parameter Number of Turns Wire Size, AWG Filar Layers Start Pin(s) Termination Pin(s) Shield Information Parameter Number of Turns Wire Size, AWG Filar Layers Start Pin(s) Termination Pin(s)
Section 1 72 28 1 2.69 3 1
Value 10 28 2 0.75 5 4
Primary 7 27 2 0.58 NC 1,2 13 28 2 0.97 1,2 NC
Cancellation
Secondary Winding (Manual Input) Parameter Spec Voltage, V Spec Current, A Actual Voltage, V Number of Turns Wire Size, AWG Filar Layers Start Pin(s) Termination Pin(s)
Output 1 (main) 8.00 3.00 8.00 8 27 2 0.90 10 6
Winding Instruction Cancellation Shield Winding Start on pin(s) 1,2 and wind 13 turns (x 2 filar) of item [6]. in exactly 1 layer. Leave this end of
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
the bobbin. Add 1 layer of tape, item [3], to secure the winding in place. Primary Winding Start on pin(s) 3 and wind 72 turns of item [6] in 3.00 layer(s) from left to right. Add 1 layer of tape, item [4], in between each primary winding layer. At the end of 1st layer, continue to wind the next layer from right to left. At the end of 2nd layer, continue to wind the next layer from left to right. On the final layer, spread the winding evenly across entire bobbin. Finish winding on pin(s) 1. Add 1 layer of tape, item [3], for insulation. Bias Winding Start on pin(s) 5 and wind 10.0 turns (x 2 filar) of item [6]. Spread the winding evenly across entire bobbin. Finish on pin(s) 4. Add 1 layer of tape, item [3], for insulation. Primary Balanced Shield Winding Start on any (temp) pin on the secondary side and wind 7 turns (x 2 filar) of item [8]. Spread the winding evenly across entire bobbin. Finish this winding on pin(s) 1,2. Cut out wire connected to temp pin on secondary side. Leave this end of primary shield winding not connected. Bend the end 90 deg and cut the wire in the middle of the bobbin. Add 3 layers of tape, item [3], for insulation. Secondary Winding Start on pin(s) 10 and wind 8 turns (x 2 filar) of item [7]. Spread the winding evenly across entire bobbin. Finish on pin(s) 6. Add 2 layers of tape, item [3], for insulation. Core Assembly Assemble and secure core halves. Item [1]. Varnish Dip varnish uniformly in item [5]. Do not vacuum impregnate.
Comments 1. For non-margin wound transformers use triple insulated wire for all secondary windings. Materials Item [1] [2] [3] [4] [5] [6] [7] [8] Description Core: EI25, NC-2H or Equivalent, gapped for ALG of 133 nH/t^2 Bobbin: Generic, 5 pri. + 5 sec. Barrier Tape: Polyester film 9.80 mm wide Separation Tape: Polyester film 9.8 mm wide Varnish Magnet Wire: 28 AWG, Solderable Double Coated Triple Insulated Wire: 27 AWG Magnet Wire: 27 AWG, Solderable Double Coated
Electrical Test Specifications
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Page 9 of 22
DER-100
24W Flyback Power Supply - TOP245
Condition 60 Hz 1 minute, from pins 1 - 5 to pins 6 - 10. Measured at 1 V pk-pk, typical switching frequency, between pin 1 to pin 3, with all other Windings open. Measured between Pin 1 to Pin 3, with all other Windings shorted.
December 7, 2005
Spec 3000 754 +/- 10%
Parameter Electrical Strength, VAC Nominal Primary Inductance, uH
Primary Leakage, uH
22.63 Goal
Page 10 of 22
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
6 Transformer Design Spread Sheet
Design Passed
EI25 Vout 1: 8.00 V, 3.00 A CLAMP 72T 8T RTN
Vin 85-265 V EMI AC & Rectifier UV/OV ILim Cin D L TOP245Y 10T
Vbias: 10.0 V, 0.006 A
CONTROL C Feedback User Defined S X F
From Vout 1
Design Results
Power Supply Input Var VACMIN VACMAX FL TC Z N 85 265 50 2.44 0.57 77.0 % Value Output 1. (main) Volts Volts Hertz mSeconds Units Description Min Input AC Voltage. Max Input AC Voltage Line Frequency Diode Conduction Time Loss Allocation Factor Efficiency Estimate
Power Supply Outputs Var VOx IOx VB IB
Value
Output 1. (main) 8.00 3.00
Units Volts Amps Volts Amps
Description Output Voltage Output Current Bias Voltage Bias Current
10.0 0.006
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DER-100
Device Variables Var Device PO VDRAIN VDS FS KRPKDP KI ILIMITEXT ILIMITMIN ILIMITMAX IP IRMS DMAX
24W Flyback Power Supply - TOP245
December 7, 2005
Value TOP245Y 24.1 559 4.83 66000 0.78 0.75 1.26 1.67 1.93 1.14 0.50 0.45
Output 1. (main)
Units
Description PI Device Name Total Output Power Maximum Drain Voltage Drain to Source Voltage Switching Frequency Continuous/Discontinuous Operating Ratio KI Factor Device Current Limit External Minimum Current Limit Minimum Current Limit Maximum Peak Primary Current Primary RMS Current Maximum Duty Cycle
Watts Volts Volts Hertz
Amps Amps Amps Amps Amps
Power Supply Components Selection Var Value VBRIDGE IAVG CIN VMIN VMAX VCLO PZ VDB PIVB 600 0.32 100.0 98.6 374.8 130 1.3 0.70 61
Output 1. (main) Volts Amps
Units
Description Diode Bridge Voltage Rating Average Diode Bridge Current Input Capacitance Minimum DC Input Voltage Maximum DC Input Voltage Clamp Zener Voltage Primary Zener Clamp Loss Bias Diode Forward Voltage Drop Bias Rectifier Max Peak Inverse Voltage
uFarads Volts Volts Volts Watts Volts Volts
Power Supply Output Parameters Var Value VDx PIVSx
Output 1. (main) 0.70 50
Units Volts Volts
Description Output Winding Diode Forward Voltage Drop Output Rectifier
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
Maximum Peak Inverse Voltage Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current
ISPx ISRMSx IRIPPLEx
10.01 4.81 3.76
Amps Amps Amps
Transformer Construction Parameters Var Value Core/Bobbin Core Manuf. Bobbin Manuf LP NP NB AWG CMA VOR BW M L AE ALG BM BP BAC LG LL Page 13 of 22 LSEC EI25 Generic Generic 686 71.7 9.8 28 322 78.00 9.80 0.0 3.00 41.00 133 2668 3369 1041 0.362 10.3 20
Output 1. (main)
Units
Description Core Type Core Manufacturer Bobbin Manufacturer
uHenries
Primary Inductance Primary Number of Turns Bias Winding Number of Turns
AWG Cmils/A Volts mm mm
Primary Wire Gauge Primary Winding Current Capacity Reflected Output Voltage Bobbin Winding Width Safety Margin Width Primary Number of Layers
mm^2 nH/T^2 Gauss Gauss Gauss mm
Core Cross Sectional Area Gapped Core Effective Maximum Flux Density Peak Flux density AC Flux Density for Core Loss Estimated Gap Length Power Integrations Leakage Inductance Secondary Trace Inductance
Tel: +1 408 414 9200 Fax: +1 408 414 9201 uHenries Primary www.powerint.com
nHenries
DER-100
LSEC 20
24W Flyback Power Supply - TOP245
nHenries
December 7, 2005
Secondary Trace Inductance
Secondary Parameters Var Value NSx Rounded Down NSx Rounded Down Vox 8.0
Output 1. (main)
Units
Description Secondary Number of Turns Rounded to Integer Secondary Number of Turns Auxiliary Output Voltage for Rounded down to Integer Secondary Number of Turns Rounded to Next Integer Secondary Number of Turns Auxiliary Output Voltage for Rounded up to Next Integer Secondary Number of Turns
Volts
Rounded Up NSx
Rounded Up Vox
Volts
AWGSx Range
17 - 21
AWG
Page 14 of 22
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
7 Performance Data
7.1 Line and Load Regulation
Figure 3 - Output Line/Load Regulation
7.2
Efficiency
Figure 4 - Efficiency
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
8 Waveforms
8.1 Output Voltage Startup
Figure 5 - Vin = 90 VAC, LOAD = 3 A V: 2V/div; T: 2msec/div
Figure 6 - Vin = 265 VAC, LOAD = 3 A V: 2V/div; T: 2msec/div
8.2
Drain Voltage / Current
Figure 7 - Vin = 90 VAC, LOAD = 3 A Top: Drain Current (1A/div) Bottom: Drain Voltage (100V/div); T: 5sec/div
Figure 8 - Vin = 265 VAC, LOAD = 3 A Top: Drain Current (1A/div) Bottom: Drain Voltage (200V/div); T: 5sec/div
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DER-100 8.3
24W Flyback Power Supply - TOP245
December 7, 2005
Output Ripple Measurements
8.3.1 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 9 and Figure 10. 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 9 - Oscilloscope Probe Prepared for Ripple Measurement
(End Cap and Ground Lead Removed)
Figure 10 - 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-100
24W Flyback Power Supply - TOP245
December 7, 2005
8.3.2 Output Voltage Ripple
Figure 11 - Output Ripple, 3 A Load, 90 VAC V: 200mV/div; T: 5sec/div
Figure 12 - Output Ripple, 3 A Load, 90 VAC V: 200mV/div; T: 2msec/div
Figure 13 - Output Ripple, 3 A Load, 265 VAC V: 200mV/div; T: 5sec/div
Figure 14 - Output Ripple, 3 A Load, 265 VAC V: 200mV/div; T: 2msec/div
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
9 EMI Tests
A conducted EMI scan of the prototype was taken to determine the effectiveness of the input filter and transformer ESHIELD(R) construction. The following plots show the peak spectra of the converter against quasi-peak (QP) and average (AVG) limits of EN55022 Class B. Both scans were taken at 120 VAC / 60Hz input with maximum load applied to the outputs. Since the peak scans are below the average limits, it is expected that the QP and Average scans would have greater than 10db of margin below the limits.
Figure 15 - EMI Test Results, 3 A Load, 120 VAC (Line)
Figure 16 - EMI Test Results, 3 A Load, 120 VAC (Neutral)
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
10 Revision History
Date September 12, 2005 December 7, 2005 Author RSP RSP Revision 1.0 2.0 Description & changes Initial Release Edit schematic to see cut-off area Reviewed AM / VC VC
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
For the latest updates, visit our Web site: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES 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 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 2004, Power Integrations.
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 CHINA (SHANGHAI) Rm 807, Pacheer, Commercial Centre, 555 Nanjing West Road, Shanghai, 200041, China Phone: +86-21-6215-5548 Fax: +86-21-6215-2468 e-mail: chinasales@powerint.com CHINA (SHENZHEN) Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu, Shenzhen, Guangdong, 518031, China Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE GERMANY Rueckertstrasse 3, D-80336, Munich, Germany Phone: +49-895-527-3910 Fax: +49-895-527-3920 e-mail: eurosales@powerint.com JAPAN 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 KOREA 8th Floor, DongSung Bldg. 17-8 Yoido-dong, Youngdeungpo-gu, Seoul, 150-874, Korea Phone: +82-2-782-2840 Fax: +82-2-782-4427 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.co m TAIWAN 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
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DER-100
24W Flyback Power Supply - TOP245
December 7, 2005
World Wide +1-408-414-9660 World Wide +1-408-414-9760 ER or EPR template - Rev 3.6 - Single sided
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