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Design Example Report
Title 21W (45W peak) Multiple Output Power Supply using TOP246Y
Input: 90 - 265 VAC Specification Output: 12V / 0.72A (2.75APK), 5V / 1.4A, 3.3V / 1.51A, 3V / 0.1A, -22V/4mA Application Author Document Number Date Revision DVD Recorder with HDD Power Integrations Applications Department DER-40 February 22, 2005 3.0
Summary and Features
* * * * * * No linear regulators used One transformer solution Small 6.8 mH common mode choke, small X-cap and Y-cap EMI has 12 dB margin Good cross regulation Small heatsinks Good peak power capability (can operate down to 75 Vac) EEL25 transformer does not use triple insulated wire, or Teflon sleeving
* * *
Meets low power standby 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-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
Table Of Contents
1 2 3 4 5 Introduction ................................................................................................................... 4 Photograph.................................................................................................................... 4 Power Supply Specification........................................................................................... 5 Schematic ..................................................................................................................... 6 Circuit Description ......................................................................................................... 8 5.1 Input EMI Filtering .................................................................................................. 8 5.2 TOPSwitch Primary................................................................................................ 8 5.3 Outputs................................................................................................................... 8 5.4 Output Feedback.................................................................................................... 8 5.5 Rev 2 to Rev3 changes.......................................................................................... 9 6 PCB Layout ................................................................................................................. 10 7 Bill Of Materials ........................................................................................................... 11 8 Transformer Specification ........................................................................................... 13 8.1 Electrical Diagram ................................................................................................ 13 8.2 Electrical Specifications ....................................................................................... 13 8.3 Materials............................................................................................................... 14 8.4 Transformer Build Diagram .................................................................................. 14 8.4.1 WD#3 Copper Foil build diagram: ................................................................. 15 8.4.2 WDG#4 & #5 Copper Foil build diagram: ...................................................... 15 8.5 Transformer Construction..................................................................................... 16 8.6 Transformer Spreadsheets................................................................................... 17 9 Performance Data ....................................................................................................... 20 9.1 Regulation in DVD Recording Mode .................................................................... 20 9.2 Efficiency.............................................................................................................. 20 9.3 Standby Input Power............................................................................................ 21 9.4 Peak Load Margin ................................................................................................ 21 10 Thermal Performance .............................................................................................. 22 11 Control Loop Measurements.................................................................................... 23 11.1 110 VAC Maximum Continuous Load .................................................................. 23 11.2 230 VAC Maximum Continuous Load .................................................................. 23 12 Waveforms............................................................................................................... 24 12.1 Drain Voltage Normal Operation .......................................................................... 24 12.2 Output Voltage Start-up Profile ............................................................................ 24 12.3 Drain Voltage Start-up Profile............................................................................... 26 13 Conducted EMI ........................................................................................................ 27 13.1 230V High Line EMI ............................................................................................. 27 13.2 110V Low Line EMI .............................................................................................. 28 14 Revision History....................................................................................................... 29
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
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.
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
1 Introduction
This document is an engineering report describing the PSU design using TOP246Y. This design adopts a one transformer solution instead of two transformers as originally used in the application, eliminates one X-cap, several Y-caps, a linear regulator and several heatsinks, and uses a smaller transformer. The new design meets EMI and peak power with good margin. The use of a smaller transformer is made possible by TOPSwitch-GX's high switching frequency with good switching performance, and the low EMI with a low-cost filter is made possible because of TOPSwitch-GX's frequency jitter and E-ShieldTM transformer winding techniques. EcoSmartTM features allow low consumption during lower power standby mode. This document contains the power supply specifications, schematic, Bill of materials, transformer documentation, printed circuit layout, and performance data.
2 Photograph
Figure 1 - Circuit Board Photograph.
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
3 Power Supply Specification
The load currents below are actual measurements of the DVD/R unit. The capability of the PSU design is higher than the measured consumption of the unit.
Description Input Voltage Frequency 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 (FL) Output Ripple Voltage 4 Output Current 4 Output Voltage 5 Output Ripple Voltage 5 Output Current 5 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Safety Ambient Temperature Symbol VIN fLINE VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 VOUT5 VRIPPLE5 IOUT5 POUT POUT_PEAK 4.75 Min 90 47 3.135 Typ Max 265 64 3.465 Units VAC Hz V mV A 5.25 V mV A V mV A V mV A V mV A Comment
2 Wires System
50/60 3.3 150 1.51 5.0 150 1.40 12 240 0.72 3.0 0.1
20 MHz Bandwidth for all the outputs
10.5
13.5 2.75 3.5
2.5
-19.8
-22.0 280 0.004
-24.2
21 45 74
W W %
Actual load measurement Measured at POUT (21W), 25 oC
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
TAMB
25
o
C
Free convection, sea level
Note: When the maximum input power happens, only 12V output shows a significantly higher peak power. All other outputs are specified at average output current at DVD drive recorder mode.
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
4 Schematic
Figure 2 - Schematic (Primary side).
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
Figure 3 -Schematic (Secondary side)
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
5 Circuit Description
The schematic in Figure 2 shows an off-line flyback converter using the TOP246Y. The circuit is designed for 90 VAC to 265 VAC input. The schematic in Figure 3 shows the secondary circuit to supply the power rails to the DVD circuits, with associated power rail control for low power modes. 5.1 Input EMI Filtering Capacitors C1, C2, X-capacitor C30, and common-mode choke L1 act as an input filter to reduce common mode and differential mode EMI. The X capacitor and Common Mode choke required in this design to achieve low EMI is very small and low cost, because of the frequency `jitter' (modulation) feature of the TOPSwitch-GX. 5.2 TOPSwitch Primary The AC line voltage is rectified and filtered to generate a high voltage DC bus via D1-4 and C1 and C2. Diode D5, C6, and R4, and R45 clamp leakage spikes generated when the MOSFET in U1 switches off. D5 is a glass-passivated normal recovery rectifier. The slow, controlled recovery time of D5 allows energy stored in C6 to be recycled back to the high voltage bus, significantly increasing efficiency. A normal (non-glass-passivated) 1N4007 should not be substituted for the glass-passivated device. C5 bypasses the U1 control pin. C4 has three functions. It provides the energy required by U1 during startup, sets the autorestart frequency during fault conditions, and also acts to roll off the gain of U1 as a function of frequency. R8 adds a zero to the control loop to help stabilize the power supply control loop. Diode D6 and capacitor C3 provide rectified and filtered bias power for U1 and U2. Components Q1, D7, C7, C28 R5, R6, R7, R39, R48 provide a signal to the U1 X pin to allow aggressive frequency reduction at light load, reducing power consumption. 5.3 Outputs The T1 output is rectified and filtered by Diodes D8-D12 and filtered by inductor/capacitor networks on most outputs. MOSFETs Q3, Q4 and Q5 are used to switch the low supply rails. Darlington device Q2 is used to switch the 12V rail. Level shifting transistors Q8-Q14 are used to drive the rail switch devices in response to logic signals PWR_CNTL1-4. 5.4 Output Feedback Output feedback is used from a combination of the 5 V and the 3.3 V rails. Resistors R31 and R30 develop a feedback voltage, which is fed to the reference regulator U3. U3 drives optocoupler U2 through resistor R27 to provide feedback information to the U1 control pin. The optocoupler output also provides power to U1 during normal operating conditions. Capacitor C20 applies drive to the optocoupler during supply startup to reduce output voltage overshoot. Capacitor C21 and R29 provide frequency compensation for error amplifier U3.
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
5.5 Rev 2 to Rev3 changes OV/UV resistor from L pin was added to provide additional protection, using the TOPSwitch-GX integrated under-voltage / over-voltage feature. The X-pin frequency reduction circuit was also modified for improved margin. Add RT1, RV1, R46, R38, R47, R37, R48, C28 Updated Gain/Phase plot C7 from 47nF to 470nF C21 from 10nF to 100nF R6 from 18k to 68k R7 from 16k to 3.6k R27 from 470 to 82 VR6
Changes
Delete
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
6 PCB Layout
Figure 4 - Printed Circuit Layout
Note: R32 is not stuffed on the PCB.
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Page 10 of 30
DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
7 Bill Of Materials
Item Qua. Value 1 2 2 68 uF 1 22 uF Part Ref. C1 C2 C3 Description 68 uF, 400 V, Electrolytic, Low ESR, 530 mOhm, (18 x 25) 22 uF, 50 V, Electrolytic, Very Low ESR, 340 mOhm, (5 x 11) 3 4 5 2 47 uF 5 100 nF 1 1 nF C4 C20 47 uF, 16 V, General Purpose, (5 x 11) ECU-S1H104KBB NCD102K1KVY5F Any Panasonic NIC Components Corp 6 7 1 470 nF 2 1000 uF C7 C8 C29 470 nF, 50 V, Ceramic, X7R 1000 uF, 25 V, Electrolytic, Very Low ESR, 21 mOhm, (12.5 x 20) 8 9 2 220 uF 1 1500 uF C9 C22 C10 220 uF, 25 V, Electrolytic, Low ESR, 120 mOhm, (8 x 12) 1500 uF, 10 V, Electrolytic, Very Low ESR, 22 mOhm, (10 x 25) 10 1 2200 uF C11 2200 uF, 10 V, Electrolytic, Very Low ESR, 21 mOhm, (12.5 x 20) 11 6 220 uF C12 C13 C23 C24 C25 C26 12 13 1 56 uF 1 100 uF C14 C15 220 uF, 10 V, Electrolytic, Low ESR, 250 mOhm, (6.3 x 11.5) 56 uF, 35 V, Electrolytic, Low ESR, 250 mOhm, (6.3 x 11.5) LXZ35VB56RMF11LL 100 uF, 10 V, Electrolytic, Very Low ESR, 300 mOhm, (5 x KZE10VB101ME11LL 11) 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 2 100 uF 1 390 pF 1 47 nF 1 1 nF 5 1N4007GP 1 BAV20 1 1N4148 1 BYV27-200 1 SB560 1 SB540 1 UF4003 1 UF4001 3 1N4001 2 1N5817 1 2A 1 CON3 4 DVD/RW 1 P/Ctrl 1 PS1 1 PS2 1 6.8 mH 3 3.3 uH 4 Mounting holes 4 2N3906 1 TIP105 4 SI2306DS 1 MPS6601 4 2N3904 1 200 k C16 C27 C28 C30 C31 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D16 D17 D14 D15 F1 J1 J2 J3 J4 J5 J6 J7 J8 L1 L2 L3 L4 M1 M2 M3 M4 Q1 Q12 Q13 Q14 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 R4 100 uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) 390 pF, 50 V, Ceramic, COG 47 nF, 275 VAC, Film, X2 1 nF, Ceramic, Y1 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 200 V, 200 mA, Fast Switching, 50 ns, DO-35 75 V, 300 mA, Fast Switching, DO-35 200 V, 2 A, Ultrafast Recovery, 25 ns, SOD57 60 V, 5 A, Schottky, DO-201AD 40 V, 5 A, Schottky, DO-201AD 200 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 50 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 50 V, 1 A, Rectifier, DO-41 20 V, 1 A, Schottky, DO-41 2 A,250V, Slow, TR5 3 Position (1 x 3) header, 0.156 pitch, Vertical 4 Position (1 x 4) header, 0.1 pitch, Vertical 5 Position (1 x 5) header, 0.1 pitch, Vertical 10 Position (1 x 10) header, 0.1 pitch, Vertical 8 Position (1 x 8) header, 0.1 pitch, Vertical 6.8 mH, 0.8 A, Common Mode Choke 3.3 uH, 2.66 A PCB Terminal Hole, 18 AWG PNP, Small Signal BJT, 40 V, 0.2 A, TO-92 PNP Darlington, Power BJT, 60 V, 8 A, TO-220 20 V, N-Channel, SOT 23 NPN, Small Signal BJT, TO-92 NPN, Small Signal BJT, 40 V, 0.2 A, TO-92 200 k, 5%, 1/2 W, Carbon Film KME10VB101M5X11LL ECU-S1H391JCA B81130B1473M 440LD10 1N4007GP BAV20 1N4148 BYV27-200 SB560 SB540 UF4003 UF4001 1N4001 1N5817 3,721,200,041 26-48-1031 22-28-4049 22-28-4050 22-28-4100 22-28-4080 ELF15N008 822LY-3R3M N/A 2N3906 TIP105 SI2306ADS MPS6601 2N3904 CFR-50JB-200K United Chemi-Con Panasonic Epcos Vishay Vishay Vishay Vishay Philips Vishay Vishay Vishay Vishay Vishay Vishay Wickman Molex Molex Molex Molex Molex Panasonic Toko N/A Fairchild Fairchild Vishay On Semiconductor Fairchild Yageo United Chemi-Con United Chemi-Con LXZ10VB221MF11LL United Chemi-Con KZE10VB222MK20LL United Chemi-Con LXZ25VB221MH15LL KZE10VB152MJ25LL United Chemi-Con United Chemi-Con ECU-S1H474KBB KZE25VB102MK20LL Panasonic United Chemi-Con Mfg Part Number KMX400VB68RM18X25LL KZE50VB22RME11LL Mfg United Chemi-Con United Chemi-Con
C5 C17 C18 C19 C21 100 nF, 50 V, Ceramic, X7R C6 1 nF, 1 kV, Disc Ceramic
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DER-40
43 44 45 46 47 48 49 1 240 1 68 k 1 3.6 k 1 6.8 1 11.8 k 1 68 5 4.7 k R5 R6 R7 R8 R9 R10
DVD/RW HDD PSU using TOP246Y
240 R, 5%, 1/8 W, Carbon Film 68 k, 5%, 1/8 W, Carbon Film 3.6 k, 5%, 1/4 W, Carbon Film 6.8 R, 5%, 1/8 W, Carbon Film 11.8 k, 1%, 1/4 W, Metal Film 68 R, 5%, 1/4 W, Carbon Film 4.7 k, 5%, 1/8 W, Carbon Film
February 22, 2005
CFR-12JB-240R CFR-12JB-68K CFR-25JB-3K6 CFR-12JB-6R8 MFR-25FBF-11K8 CFR-25JB-68R CFR-12JB-4K7 Yageo Yageo Yageo Yageo Yageo Yageo Yageo
R11 R14 R20 R21 R23
50
7 20 k
R12 R13 R18 R22 R26 R29 R34
20 k, 5%, 1/8 W, Carbon Film
CFR-12JB-20K
Yageo
51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73
2 510 k 1 510 k 1 100 k 3 47 k 1 82 2 10 k 1 10 k 1 16.5 k 1 37.4 k 1 22 k 11 1 1k 3 1M 3 22 k 2 4.7 M 1 30 1 30 k 1 16 1 320 Vac 1 EEL25 1 TOP246Y 1 PC817D 1 LMV431_A
R15 R17 R16 R19 R24 R25 R35 R27 R28 R39 R30 R31 R32 R33 R36 R37 R38 R46 R47 R40 R43 R44 R41 R42 R45 R48 RT1 RV1 T1 U1 U2 U3
510 k, 5%, 1/4 W, Carbon Film 510 k, 5%, 1/8 W, Carbon Film 100 k, 5%, 1/8 W, Carbon Film 47 k, 5%, 1/8 W, Carbon Film 82 R, 5%, 1/4 W, Carbon Film 10 k, 5%, 1/8 W, Carbon Film 10 k, 1%, 1/4 W, Metal Film 16.5 k, 1%, 1/4 W, Metal Film 37.4 k, 1%, 1/4 W, Metal Film 22 k, 5%, 1/4 W, Carbon Film 1 R, 5%, 1/4 W, Carbon Film 1 k, 5%, 1/4 W, Carbon Film 1 M, 5%, 1/4 W, Carbon Film 22 k, 5%, 1/8 W, Carbon Film 4.7 M, 5%, 1/8 W, Carbon Film 30 R, 5%, 1/2 W, Carbon Film 30 k, 5%, 1/4 W, Carbon Film NTC Thermistor, 16 Ohms, 1.7 A 320 V, 26 J, 7 mm, RADIAL Custom TOPSwitch-GX, TOP246Y, TO220-7C Opto coupler, 35 V, CTR 80-160%, 4-DIP 1.24V Shunt Reg IC
CFR-25JB-510K CFR-12JB-510K CFR-12JB-100K CFR-12JB-47K CFR-25JB-82R CFR-12JB-10K MFR-25FBF-10K0 MFR-25FBF-16K5 MFR-25FBF-37K4 CFR-25JB-22K CFR-25JB-1R0 CFR-25JB-1K0 CFR-25JB-1M0 CFR-12JB-22K CFR-12JB-4M7 CFR-50JB-30R CFR-25JB-30K CL180 V320LA7
Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Thermometrics Littlefuse
TOP246Y ISP817A, PC817X1 LMV431ACZ
Power Integrations Isocom, Sharp National Semiconductor
74 75 76 77 78 79
1 1N4737A 1 1N5229B 1 1N5251B 1 1N5239B 1 P6KE200A 1
VR1 VR2 VR3 VR4 VR5 H1
7.5 V, 5%, 1 W, DO-41 4.3 V, 5%, 500 mW, DO-35 22 V, 5%, 500 mW, DO-35 9.1 V, 5%, 500 mW, DO-35 200 V, 5 W, 5%, DO204AC (DO-15) Heatsink
1N4737A 1N5229B 1N5251B 1N5239B P6KE200A
Diodes Inc. Microsemi Microsemi Microsemi Vishay Any
Note: Item 79, H1 heatsink, is a plain sheet metal heatsink 11x24x0.5 mm with a solderable tab at one end. It is soldered onto cathode of D9, which is an axial diode. Material used on the prototype was copper but plated mild steel can be used.
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
8 Transformer Specification
8.1 Electrical Diagram
1 WD#1 Cancellation 15T #30 x 2 4T # 30 x 2 NC WD#2 First Half Primary 3 28T #29 2 WD#3 Shield 1T CU Foil 1 WD#9 Bias & Cancellation WD#10 Cancellation WD#11 Second Half Primary 6 7T #30 x 2 7 8T #30 x 2 1 28T #29 3 2T # 30 8 9 WD#7 3V FL O/P 10 2T CU Foil 12 12T # 29 x 2 13 1T CU Foil 11 WD#5 5V O/P 14 WD#6 12V O/P
WD#4 3.3V O/P
WD#8 -22V O/P
Figure 5 -Transformer Electrical Diagram
8.2
Electrical Specifications
1 second, 60 Hz, from Pins 1 - 7 to Pins 8 -14 Pins 1-2, all other windings open, measured at 132 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with Pins 7-14 shorted, measured at 132 kHz, 0.4 VRMS 3000 VAC 422 uH, -10/+10% 1M kHz (Min.) 10 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
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DER-40 8.3 Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10]
DVD/RW HDD PSU using TOP246Y
February 22, 2005
Description
Core: PC40EEL25, TDK or equivalent Gapped for AL of 134 nH/T2 Bobbin: EEL25, Horizontal 14 pins Magnet Wire: #30 AWG Magnet Wire: #29 AWG Magnet Wire: #28 AWG WD#3, CU Foil: 2mil x 10mm wide x 50 mm long WD#4&5 CU Foil: 2mil x 9mm wide x 134 mm long Tape: Margin 6 mm Tape: 3M 1298 Polyester Film, 10.6mm wide Tape: 3M 1298 Polyester Film, 22.4mm wide
8.4
Transformer Build Diagram
1 3 7 6
WD#11 Second Half Primary WD#9 & WD#10 Bias & Cancellation
10
WD#8 -22V O/P WD#7 3V FL O/P WD#6 12V O/P WD#4 & WD#5 3.3V & 5V O/P
1 3 2
12 8 9 13 14 13 11 12
WD#3 Shield WD#2 First Half Primary
1
WD#1 Cancellation
Figure 6 - Transformer Build Diagram.
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
8.4.1 WD#3 Copper Foil build diagram:
Cu Foil 1mil; 10mm W x 46mm L 1-layer tape folded
44mm 28 AWG
Figure 7 - Copper Foil Build Diagram.
8.4.2 WDG#4 & #5 Copper Foil build diagram:
Cu Foil 1mil; 9mm W x 134mm 1-layer tape folded
45mm 28 AWG X 2 28 AWG X 2
86mm 28 AWG X 4 Start from this end, reverse wind
Figure 8 - Copper Foil Build Diagram
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
8.5
Transformer Construction
Bobbin Preparation Margin Tape WD#1 Cancellation Insulation WD#2 Fist Half Primary Insulation WD #3 Shield Insulation Margin Tape WD #4 & WD #5 Insulation WD #6 Pin1 side of the bobbin orients to the left hand side. Wind item [8] at the each pin side of the bobbin to match the height of the first half primary windings. Start on Pin 1, wind 15 turns bifilar of item [3] from left to right. Wind with th tight tension. Cut the wires after finishing 15 turns. Overall, total 15 turns winding should be well fit the entire length of the bobbin. 2 Layers of tape [9] for insulation Start on pin 2, wind 28 turns of item [4] from left to right. After finishing the 28th turns, All the wires should be well fit the entire length of the bobbin. Bring the lead back to the left side and finish it on Pin 3. 1 Layer of tape [9] for insulation. Start at Pin 1, wind 1turns of item [6]. Clock-wise wind with tension. Apply a small piece tape to secure the end of the foil. 3 Layers of tape [10] for insulation. Wind item [8] at the each pin side of the bobbin to match the height of the secondary windings. Start at pin 12, anti-clock-wise wind 2 turns of item [7]. Wind with tight. Finish the middle termination to pin 11, then continue to wind the last turn and finish it on pin 13. Apply a piece of tape to secure the end of the foil 1 Layer of tape [9] for insulation. Start at pin 14, wind 4 turns bifilar of item [3] from right to left. Wind uniformly, in a single layer across entire bobbin evenly. Bring the wire back and finish on pin 13. Start at pin 9, wind 2 turns of item [3] from right to left. Wind between the wire gaps of the previous winding, in a single layer across entire bobbin evenly. Bring the wire back and finish on pin 8. 1 Layer of tape [9] for insulation. Start at pin 12, wind 12 turns bifilar of item [4] from right to left. Wind uniformly, in a single layer across entire bobbin evenly. Bring the wire back and finish on pin 10. 3 Layers of tape [10] for insulation. Start on Pin 6, wind 7 turns bifilar of item [3] from left to right. Wind with th tight tension. After finishing 7 turn, bring the wire back and finish it on Pin 7. Start from the Pin 7, rout the same wires to the ending position of the previous winding, continuous to wind another 8 turns, cut the wires th after finishing 8 turns. Overall, total 15 turns winding should be well fit the entire length of the bobbin. 1Layer of tape [9] for insulation. Start on pin 3, wind 28 turns of item [4] from left to right. After finishing the th 28 turns, All the wires should be well fit the entire length of the bobbin. Bring the lead back to the left side and finish it on Pin 1. 3 Layers of tape [10] for insulation. Grind the core to get 422uH. Secure the core with tape.
WD #7 Insulation WD #8 Insulation
WD #9 & WD10
Insulation WD #11 Insulation Finish
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
8.6
Transformer Spreadsheets
INPUT INFO INFO OUTPUT OUTPUT UNIT TOP_GX_FX_032204.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet
ACDC_TOPSwitchGX_032204; Rev.1.9; Copyright Power Integrations Inc. 2004
ENTER APPLICATION VARIABLES
VACMIN VACMAX fL VO PO n Z VB tC CIN 90 265 50 5 45 0.73 0.5 15 3 136 Volts Volts Volts Hertz Volts Watts
Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Bias Voltage
mSeconds Bridge Rectifier Conduction Time Estimate uFarads Input Filter Capacitor
ENTER TOPSWITCH-GX VARIABLES
TOP-GX Chosen Device
TOP246
TOP246 TOP246 Power Out Power Out
Universal 90W
115 Doubled/230V 125W
KI
0.7
External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT)
ILIMITMIN ILIMITMAX Frequency (F)=132kHz, (H)=66kHz fS F
1.701 2.079
1.701 Amps 2.079 Amps
Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Full (F) frequency option - 132kHz
132000
132000 Hertz
TOPSwitch-GX Switching Frequency: Choose between 132 kHz and 66 kHz
fSmin fSmax VOR VDS VD VDB KP 103 10 0.5 0.7 0.55
124000 140000
124000 Hertz 140000 Hertz Volts Volts Volts Volts
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)
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type Core Bobbin
eel25
EEL25 EEL25_BOBBIN EEL25 EEL25_BOBBIN 0.404 7.34 1420 22.3 6 P/N: P/N: 0.404 cm^2 7.34 cm 1420 nH/T^2 22.3 mm mm PC40EE25.4/32/6.4-Z * 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)
AE LE AL BW M
L NS
2 3
Number of Primary Layers Number of Secondary Turns
DC INPUT VOLTAGE PARAMETERS
VMIN 99 99 Volts Minimum DC Input Voltage
Page 17 of 30
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DER-40
VMAX
DVD/RW HDD PSU using TOP246Y
375 375 Volts
February 22, 2005
Maximum DC Input Voltage
CURRENT WAVEFORM SHAPE PARAMETERS
DMAX IAVG IP IR IRMS 0.54 0.62 1.60 0.88 0.87 0.54 0.62 Amps 1.60 Amps 0.88 Amps 0.87 Amps Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP NP NB ALG BM BP BAC 422 56 9 134 2972 3864 817 422 uHenries 56 9 134 nH/T^2 2972 Gauss 3864 Gauss 817 Gauss Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns Gapped Core Effective Inductance Maximum Flux Density at PO, VMIN (BM<3000) Peak Flux Density (BP<4200) AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) ur LG BWE OD INS 2053 0.34 20.6 0.37 0.06 2053 0.34 mm 20.6 mm 0.37 mm 0.06 mm Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) DIA AWG 0.31 29 0.31 mm 29 AWG Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) CM CMA Warning Warning 128 147 128 Cmils Bare conductor effective area in circular mils
147 Cmils/Amp !!!!!!!!!! INCREASE CMA>200 (increase L(primary layers),decrease NS,larger Core)
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT)
Lumped parameters ISP ISRMS IO IRIPPLE 29.94 15.14 9.00 12.18 29.94 Amps 15.14 Amps 9.00 Amps 12.18 Amps Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current
CMS AWGS
3028 15
3028 Cmils 15 AWG
Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value)
DIAS ODS
1.45 3.43
1.45 mm 3.43 mm
Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire
INSS
0.99
0.99 mm
Maximum Secondary Insulation Wall Thickness
VOLTAGE STRESS PARAMETERS
VDRAIN 611 611 Volts Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) PIVS PIVB 25 72 25 Volts 72 Volts Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output VO1 IO1 PO1 3.3 1.500 4.95 Volts Amps 4.95 Watts Output Voltage Output DC Current Output Power
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DER-40
VD1 NS1 ISRMS1 IRIPPLE1 PIVS1
DVD/RW HDD PSU using TOP246Y
0.5 2.07 2.524 2.03 17 2.07 2.524 Amps 2.03 Amps 17 Volts Volts
February 22, 2005
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
CMS1
505
505 Cmils
Output Winding Bare Conductor minimum circular mils
AWGS1
23
23 AWG
Wire Gauge (Rounded up to next larger standard AWG value)
DIAS1 ODS1 2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 0.7 12.0 0.700
0.58 4.97
0.58 mm 4.97 mm
Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
Volts Amps 8.40 8.40 Watts Volts 6.93 1.178 0.95 58 6.93 1.178 Amps 0.95 Amps 58 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
CMS2
236
236 Cmils
Output Winding Bare Conductor minimum circular mils
AWGS2
26
26 AWG
Wire Gauge (Rounded up to next larger standard AWG value)
DIAS2 ODS2
0.41 1.49
0.41 mm 1.49 mm
Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 0.7 12.38 0.168 0.14 105 12.38 0.168 Amps 0.14 Amps 105 Volts 22.0 0.100 2.20 Volts Amps 2.20 Watts 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
CMS3
34
34 Cmils
Output Winding Bare Conductor minimum circular mils
AWGS3
34
34 AWG
Wire Gauge (Rounded up to next larger standard AWG value)
DIAS3 ODS3
0.16 0.83
0.16 mm 0.83 mm
Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
Page 19 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. Some tests were performed using E-loads, some were performed in the actual DVD Recorder unit. The actual unit was only tested in HDD -> DVD-R recording mode, which shows the highest average and peak power draw. The DVD Recorder unit is a prototype which does not have the correct standby mode, nor the firmware to drive the control signals 1-4. So testing in the unit was done with signals 1-4 connected to 5Vsb to turn on all the switched outputs. 9.1 Regulation in DVD Recording Mode
A Fluke 87 in min/max recording mode was used to capture the min and max of each output. The test was done at room temperature, 90 Vac and 265 Vac input. Output 3.3 VSB 3.3 VSW1 3.3 VSW2 5 VSB 5 VSW1 5VSW3 12 VSB 12 VSW1 3 VFL - 22V 90V (V) 3.261 3.206 3.221 5.06 4.95 5.03 11.51 12.08 2.55 - 23.3 265V (V) 3.263 3.207 3.222 5.05 4.94 5.02 11.49 12.05 2.49 -22.6
9.2
Efficiency
E-loads were used for this measurement.
Output 3.3 VSW1 5 VSW1 12 VSW1 3 VFL - 22V Total output Power
Load Output (V) Output ( A ) 3.22 1.53 4.95 1.39 12.01 0.87 2.53 0.1 - 23 0.004
O/P Power (W) 4.927 6.881 10.45 0.253 0.092 22.60
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
Input Voltage 90Vac 265Vac 9.3 Standby Input Power
Efficiency 76.4% 78.2%
With E-load at 1W condition, 12VSB @ 2.5mA, 5VSB @20mA, Power Block 2 is loaded @340mW. Input Voltage 110 Vac 230 Vac Input Power 836mW 860mW
9.4 Peak Load Margin A Flyback power supply has lowest peak power capability at minimum AC voltage. The DVD/R unit has very fluctuating power requirements, which are difficult to characterize. It draws maximum power when switching signal inputs or inserting the DVD tray. A good test for peak power margin is to see the minimum AC voltage that the unit can operate normally. The unit is powered up at, and operated at a reduced AC input voltage. The unit is cycled through different modes of operation - startup, eject, load, play, record, etc. The DVD/RW HDD functions normally. Input voltage 75Vac Result PASS
75 Vac is a very good result and implies there is plenty of margin for peak power capability.
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
10 Thermal Performance
Test Condition: The DVD/RW HDD was set on the bench. The unit is recording (highest continuous load) during the test.
Temperature (C) Item Ambient (C) TOP246Y (U1) 5 V filter Cap (C10) 3.3 V Rectifier (D10) 5 V Rectifier (D9) 67.7 56.2 75.1 83.2 90Vac (C) 25 56.2 55.5 74.3 82.6 265Vac
Note: H1 heatsink is attached to D9.
Page 22 of 30
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
11 Control Loop Measurements
The power supply is loaded at 21W continuous load. 11.1 110 VAC Maximum Continuous Load
Figure 9 - Gain-Phase Plot, 110 VAC, 21W Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 3 kHz Phase Margin = 105
11.2 230 VAC Maximum Continuous Load
Figure 10 - Gain-Phase Plot, 230 VAC, 21W Steady State Load. Vertical Scale: Gain = 10 dB/div, Phase = 30/div. Crossover Frequency = 6.5 kHz, Phase Margin = 60
Page 23 of 30
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
12 Waveforms
Waveforms were taken at 25oC 12.1 Drain Voltage Normal Operation
Figure 11 - 265 VAC, VDRAIN, 100 V, 5 s / div
12.2 Output Voltage Start-up Profile
12V
12V
5V
5V
Figure 12 - Start-up Profile, 90 VAC 2V/div for 5V, 5V/div for 12V, 100 ms / div.
Figure 13 - Start-up Profile, 265 VAC 2V/div for 5V, 5V/div for 12V, 100 ms / div.
Page 24 of 30
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
-22V
-22V
3.3V
3.3V
Figure 14 - Start-up Profile, 90 VAC 1V/div for 3.3V, 10V/div for -22V, 200 ms / div.
Figure 15 - Start-up Profile, 265 VAC 1V/div for 3.3V, 10V/div for -22V, 200 ms / div.
5V
5V
Figure 16 - Start-up Profile, 90 VAC 1V/div for 3V FL, 500 ms / div.
Figure 17 - Start-up Profile, 265 VAC 1V/div for 3V FL, 500 ms / div.
Page 25 of 30
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
12.3 Drain Voltage Start-up Profile
Figure 18 - 90 VAC Input. VDRAIN, 100 V & 10 ms / div.
Figure 19 - 265 VAC Input. VDRAIN, 100 V & 20 ms / div.
Page 26 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
13 Conducted EMI
EMI was tested at room temperature and at 110 VAC & 230 VAC input. The TOP246Y PSU was installed in the DVD/RW HDD Recorder. The DVD/RW HDD was in recording mode during the test. Two conditions were tested. (1) Chassis connected to LISN ground (worst case), and (2) with no connection. Red line is QP, Blue line is AVG. EMI is low in spite of low-cost EMI filter because of TOP246Y built-in frequency jittering and E-ShieldTM transformer winding technique. 13.1 230V High Line EMI
Figure 20 - Line, Secondary Grounded
Figure 21 - Neutral, Secondary Grounded
Figure 22 - Line, Secondary Floating
Figure 23 - Neutral, Secondary Floating
Page 27 of 30
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DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
13.2 110V Low Line EMI
Figure 24 - Line, Secondary Grounded
Figure 25 - Neutral, Secondary Grounded
Figure 26 - Line, Secondary Floating
Figure 27 - Neutral, Secondary Floating
Page 28 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 2005
14 Revision History
Date Sept 21, 2004 Sept 29, 2004 Author DZ DZ Revision 1.0 2.0 Description & changes Initial release R1, R2, R3, R38 removed; R27 changed from 56 ohms to 470 ohms; C7 changed from 220 nF to 47 nF; R27 changed from 56 ohms to 470 ohms; small heatsink H1 is added and attached to axial diode D9; C30 is stuffed. Add OV/UV resistor; improve frequency reduction circuit, Reviewed VC / AM VC / AM
Feb 18, 2005
DZ
3.0
AM / VC
Page 29 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-40
DVD/RW HDD PSU using TOP246Y
February 22, 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 World Wide +1-408-414-9660 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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APPLICATIONS FAX World Wide +1-408-414-9760
ER or EPR template - Rev 3.6 - Single sided
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