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Design Example Report
Title 16W Power Supply using TOP243P Input: 195Vac - 265Vac Specification Output: 1.8V/600mA, 3.3V/750mA, 5V/520mA, 12V/0.8A Application Author Date Document Number Revision Set Top Box Power Integrations Applications Department April 20, 2005 DER-51 1.0
Summary and Features * * * Low cost flyback platform power supply Direct generation of 1V8, 3V3, 5V and 12V rails from transformer requires no linear post regulation. >60ms hold up time
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-51
16W STB Power Supply
April 20, 2005
Table Of Contents
Introduction................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic................................................................................................................... 6 Circuit Description ...................................................................................................... 7 4.1 Input EMI Filtering ............................................................................................... 7 4.2 TOPSwitch Primary ............................................................................................. 7 4.3 Transformer details ............................................................................................. 7 4.4 Output Feedback................................................................................................. 7 5 PCB Layout ................................................................................................................ 8 6 Bill Of Materials .......................................................................................................... 9 7 Transformer Specification......................................................................................... 10 7.1 Electrical Diagram ............................................................................................. 10 7.2 Electrical Specifications..................................................................................... 10 7.3 Materials............................................................................................................ 10 7.4 Transformer Build Diagram ............................................................................... 11 7.5 Transformer Construction.................................................................................. 11 8 Design Spreadsheet................................................................................................. 13 9 Performance Data .................................................................................................... 15 9.1 Efficiency........................................................................................................... 15 9.2 Regulation ......................................................................................................... 16 9.2.1 Line ............................................................................................................ 16 9.2.2 Cross Regulation........................................................................................ 16 10 Thermal Performance ........................................................................................... 18 11 Waveforms............................................................................................................ 19 11.1 Drain Voltage and Current, Steady State Full Power Operation........................ 19 11.2 Drain Voltage and Current Start-up Profile........................................................ 19 11.3 Output Voltage Start-up Profile ......................................................................... 20 11.4 Load Transient Response (75% to 100% Load Step) ....................................... 21 11.5 Hold-up Time..................................................................................................... 22 11.6 Output Ripple Measurements............................................................................ 24 11.6.1 Ripple Measurement Technique ................................................................ 24 11.6.2 Measurement Results ................................................................................ 25 12 Surge Test Results ............................................................................................... 27 12.1 Differential Mode Surge Tests........................................................................... 27 12.2 Common Mode Surge Tests ............................................................................. 27 13 Conducted EMI ..................................................................................................... 28 14 Revision History.................................................................................................... 29 1 2 3 4
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DER-51
16W STB Power Supply
April 20, 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.
Page 3 of 30
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DER-51
16W STB Power Supply
April 20, 2005
1 Introduction
This document is a prototype engineering report describing a 16W power supply utilizing a TOP243P. 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
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DER-51
16W STB Power Supply
April 20, 2005
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 Total Output Power Continuous Output Power Efficiency Environmental Conducted EMI Safety Surge
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Symbol VIN fLINE
Min 85 47
Typ
Max 265 64 0.3
Units VAC Hz W V mV A V mV A V mV A V mV A V mV mA W %
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 VOUT5 VRIPPLE5 IOUT5 POUT
1.8 0.3 3.3 0.4 5 0.2 12 0.01 -5 10 10 16W 77 120 0.8 50 0.52 33 0.75 18 0.6
5% 20 MHz bandwidth 5% 20 MHz bandwidth 5% 20 MHz bandwidth 5% 20 MHz bandwidth 5% 20 MHz bandwidth
Measured at POUT (16 W), 25 oC
4
kV
Surge Ambient Temperature TAMB
3 0 50
kV
o
1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: 12 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level
C
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DER-51
16W STB Power Supply
April 20, 2005
3 Schematic
Figure 2 - Schematic
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DER-51
16W STB Power Supply
April 20, 2005
4 Circuit Description
This power supply is based on a flyback converter using TOP243P. 4.1 Input EMI Filtering
Input differential mode EMI filtering is provided by the two bulk capacitors (C1 and C2) in combination with the leakage inductance of the common-mode choke, T1. Shield winding techniques have been used in the transformer to reduce common-mode noise and this has resulted in the power supply requiring only a small 5mH, 0.2A CM-Choke and 1nF Y1 capacitor. 4.2 TOPSwitch Primary
The TOP243P has been configured to give over-voltage and under-voltage shutdown protection by using the M-pin functionality. A slow 1N4007GP diode has been used in the primary side leakage clamp since it has a specified reverse recovery of about 2uS. This allows some of the clamp energy to be recycled and increases overall efficiency. A small 100R resistor is placed in series with this diode to limit the pull-out current to a safe level. The input bulk storage capacitors have been oversized to provide the required 60ms hold-up time. 4.3 Transformer details
Full transformer construction details are given in section 7. Shield windings have been used to minimize core voltage potential and to minimize primary to secondary commonmode current flow. In order to generate the 1V8, 3V3, 5V and 12V rails accurately, 3 turns are used for the 1V8, 2 extra for the 3V3, 3 extra for the 5V and 6 extra for the 12V rail. 4.4 Output Feedback
Feedback is derived from the 3V3 and 5V rails with approximately 50/50 influence split. A TL431 and opto-isolator is used to feedback to the primary.
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DER-51
16W STB Power Supply
April 20, 2005
5 PCB Layout
Figure 3 - Printed Circuit Layout
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DER-51
16W STB Power Supply
April 20, 2005
6 Bill Of Materials
Part Reference Value C1 C2 10uF, 400V C3 C16 100nF, 50V C4 C18 47uF, 10V C5 1nF, 450V C6 1uF, 50V C7 C8 C9 C10 C11 C12 C13 C15 C17 D1 D2 D3 D4 D5 D6 D11 D12 D7 D8 D13 D14 F1 L2 L3 L4 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R13 RT1 RV1 T1 T2 U1 U2 U3 220uF, 35V Description 100 nF, 50 V, Ceramic, X7R 1.0 uF, 450 V, Disc Ceramic Quantity 2 2 2 1 1 4 3 1 1 4 1 3 2 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Manufacturer Panasonic Panasonic Mfg Part Number ECU-S1H104KBB ECQ-E2W105KC
220 uF, 35 V, Electrolytic, Very Low ESR, 56 mOhm, (8 x 15) 100 uF, 16 V, Electrolytic, Low ESR, 250 mOhm, (6.3 x 11.5) 100uF, 16V 10 uF, 50 V, Electrolytic, Gen Purpose, (5 x 11.5) 10uF, 50V 1 nF, Ceramic, Y1 1nF, 250VAC 1000 V, 1 A, Rectifier, DO-41 1N4007 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 1N4007G 75 V, 300 mA, Fast Switching, DO-35 1N4148 60 V, 1.1 A, Schottky, DO-41 SB120 UG2D UG2B 1 A, 250V, Slow, TR5 1A, 250V 3.3 uH, 2.66 A 3.3uH 1 R, 5%, 1/4 W, Carbon Film 1M0 6.8 R, 5%, 1/4 W, Carbon Film 6R8 100 k, 5%, 1 W, Metal Oxide 100k 100 R, 5%, 1/4 W, Carbon Film 100R 150 R, 5%, 1/4 W, Carbon Film 150R 10 k, 5%, 1/4 W, Carbon Film 10k 3.3 k, 5%, 1/4 W, Carbon Film 3k3 10 k, 1%, 1/4 W, Metal Film 10k0 6.04 k, 1%, 1/4 W, Metal Film 6k04 20 k, 1%, 1/4 W, Metal Film 20k0 130 R, 5%, 1/4 W, Carbon Film 130 NTC Inrush resistor 10R 275 V, 45 J, 10 mm, RADIAL 275 680 uH, 0.25 A, 10mH, 0.1A Custom EF25 EF25 TOPSwitch-GX, TOP242P, DIP-8B TOP243P PC817 PC817 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO92 TL431CLP
United Chemi-Con United Chemi-Con Panasonic Vishay Vishay Vishay Vishay International Rectifier
KZE35VB221MH15LL LXZ16VB101MF11LL ECA-1HHG100 440LD10 1N4007 1N4007GP 1N4148 11DQ06
Wickman Toko Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Littlefuse Tokin Power Integrations Sharp Texas Instruments
3,721,315,041 822LY-3R3M CFR-25JB-1M0 CFR-25JB-6R8 RSF200JB-100K CFR-25JB-100R CFR-25JB-150R CFR-25JB-10K CFR-25JB-3K3 MFR-25FBF-10K0 MFR-25FBF-6K04 MFR-25FBF-20K0 CFR-25JB-130R V275LA10 SBC1-681-251 TOP242P PC817X1 TL431CLP
Page 9 of 30
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DER-51
16W STB Power Supply
April 20, 2005
7 Transformer Specification
7.1 Electrical Diagram
Figure 4 -Transformer Electrical Diagram
7.2
Electrical Specifications
1 second, 60 Hz, from Pins 1 - 5 to Pins 6 - 10 Pins 1-4, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-4, all other windings open Pins 1-4, with Pins 5-10 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 2357 H, 0/+20% 600 kHz (Min.) 70 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
7.3
Materials
Description Core: EF25, 3F3 material or magnetic equivalent Bobbin: 10 pin EF25 bobbin Magnet Wire: 0.15MM Heavy Nyleze Magnet Wire: 0.375MM Heavy Nyleze Tape: 3M Type 1298 Polyester Film or Equivalent Margin Tape 3mm wide Varnish
Item [1] [2] [3] [4] [5] [6] [7]
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DER-51
16W STB Power Supply
April 20, 2005
7.4
Transformer Build Diagram
5V Winding 1V8 and 3V3 Windings 12V Winding 5 2 1 4 1
8 9 8 6 9 10 Bias 7
Primary Core Shield
Primary
Figure 5 - Transformer Build Diagram
Secondary
7.5
Transformer Construction
Preparation Orient the bobbin with the primary on the left. Apply 3mm margin tape [6] to each side of the bobbin. Start temporarily on the right hand side of the bobbin. Wind 26 bifilar turns of item [3] from right to left over a single full layer. Don't terminate the left hand side of the winding but fix it in place with tape. Bring the right hand side of the winding across to the left hand side and terminate onto pin 1. Use two layers of item [5] for basic insulation. Start at Pin 4 on the left hand side of the bobbin. Wind 48 turns of item [3] in approximately 1 layer from left to right. Continue with one further full layer of 48 turns from right to left in a single layer. Finish with one further full layer of 48 turns from left to right. Bring finish lead back across bobbin window and terminate onto pin 1. Use two layers of item [5] for basic insulation. Start temporarily on the right hand side of the bobbin. Wind 18 turns of item [4] from right to left in a single full layer. Finish on pin 2. Bring temporary start of the winding across the bobbin and termiante on pin 5. . Use two layers of item [5] for basic insulation. Start at Pin 10 on the right hand side of the bobbin. Wind 9 birifilar turns of item [4] from right to left in a single layer. Bring the end of the winding across the bobbin and terminate onto pin 9.
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Core Shield Basic Insulation
Primary
Basic Insulation Bias Winding Basic Insulation 12V Winding
Page 11 of 30
DER-51
Basic Insulation 1V8 and 3V3 windings Basic Insulation 5V Winding Basic Insulation Final Assembly
16W STB Power Supply
April 20, 2005
Use two layers of item [5] for basic insulation Start on pin 6 on the right hand side of the bobbin. Wind 3 quadrafilar turns of item [4] from right to left, spreading evenly over the bobbin width. Finish on pin 7. Start on pin 8 on the right hand side of the bobbin. Wind 2 quadrafilar turns of item [4] from right to left, interposing the winding with the 1V8 winding. Finish on pin 6. Use two layers of item [5] for basic insulation Start on pin 10 on the right hand side of the bobbin. Wind 3 quadrafilar turns of item [4] from right to left. Terminate on pin 9. Use two layers of item [5] for basic insulation Assemble and secure core halves. Varnish impregnate.
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DER-51
16W STB Power Supply
April 20, 2005
8 Design Spreadsheet
Power Supply Input
Value Output 1 Output 2 Output 3 Output 4 Units Description (main) VACMIN 195 Volts Min Input AC Voltage VACMAX 265 Volts Max Input AC Voltage FL 50 Hertz Line Frequency TC 1.75 mSeconds Diode Conduction Time Z 0.59 Loss Allocation Factor N 85.0 % Efficiency Estimate Power Supply Outputs Var Value Output 1 Output 2 Output 3 Output 4 Units Description (main) VOx 1.80 3.30 5.00 12.00 Volts Output Voltage IOx 0.60 0.75 0.52 0.80 Amps Output Current VB 12.0 Volts Bias Voltage IB 0.006 Amps Bias Current Device Variables Output 4 Units Description Var Value Output 1 Output 2 Output 3 (main) Device TOP243P PI Device Name PO 15.8 Watts Total Output Power VDRAIN 605 Volts Maximum Drain Voltage VDS 3.25 Volts Drain to Source Voltage FS 132000 Hertz Switching Frequency KRPKDP 0.60 Continuous/Discontinuous Operating Ratio KI 1.00 KI Factor ILIMITEXT 0.70 Amps Device Current Limit External Minimum ILIMITMIN 0.70 Amps Current Limit Minimum ILIMITMAX 0.80 Amps Current Limit Maximum IP 0.37 Amps Peak Primary Current IRMS 0.14 Amps Primary RMS Current DMAX 0.28 Maximum Duty Cycle Power Supply Components Selection Var Value Output 1 Output 2 Output 3 Outp Units Description (main) ut 4 CIN 32.0 uFarads Input Capacitance VMIN 257.8 Volts Minimum DC Input Voltage VMAX 374.8 Volts Maximum DC Input Voltage VCLO 150 Volts Clamp Zener Voltage PZ 2.5 Watts Primary Zener Clamp Loss VDB 0.70 Volts Bias Diode Forward Voltage Drop PIVB 60 Volts Bias Rectifier Max Peak Inverse Voltage RLS1 4.7 MOhms Line sense resistor VUVON_MIN 207.19 Volts Minimum undervoltage threshold beyond which Power supply will startup VUVON_MAX 253.71 Volts Maximum undervoltage threshold before which Power Supply will start-up VOVOFF_MIN 979.43 Volts Minimum overvoltage threshold after which Power Supply will turn off after an over voltage condition VOVOFF_MAX 1118.99 Volts Maximum overvoltage threshold before the Power Supply will turn off after an over voltage condition Comment: Drain voltage close to
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Var
Page 13 of 30
DER-51
16W STB Power Supply
April 20, 2005
BVDSS at maximum OV threshold Tip: Verify BVDSS during line surge, decrease VUVON_MAX or reduce VOR.
Power Supply Output Parameters Var Value Output 1 Output 2 (main) VDx 0.30 0.50 PIVSx 10 18
Output 3 0.50 26 0.97 0.59 0.28
Output 4 0.70 60 1.49 0.91 0.43
Units Volts Volts Amps Amps Amps
Description Output Winding Diode Forward Voltage Drop Output Rectifier Maximum Peak Inverse Voltage Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current Units Description Core Type Core Manufacturer Bobbin Manufacturer Primary Inductance Primary Number of Turns Bias Winding Number of Turns Primary Wire Gauge Primary Winding Current Capacity Reflected Output Voltage Bobbin Winding Width Safety Margin Width Primary Number of Layers Core Cross Sectional Area Gapped Core Effective Inductance Maximum Flux Density Peak Flux density AC Flux Density for Core Loss Gap Length Primary Leakage Inductance Secondary Trace Inductance
ISPx 1.12 1.40 ISRMSx 0.68 0.85 IRIPPLEx 0.32 0.41 Transformer Construction Parameters Var Value Output 1 (main) Core/Bobbin E25/13/7 (EF25) Core Manuf. Generic Bobbin Manuf Generic LP 2357 NP 142.9 NB 18.1 AWG 35 CMA 228 VOR BW M L AE ALG 100.00 15.30 3.0 3.00 52.50 115
Output 2
Output 3
Output 4
uHenries
AWG Cmils/A Volts mm mm mm^2 nH/T^2 Gauss Gauss Gauss mm uHenries nHenries Output 2 5.4 5 3.00 Output 3 7.9 7 4.40 Output 4 18.1 18 11.90
BM 1150 BP 2520 BAC 345 LG 0.53 LL 47.1 LSEC 20 Secondary Parameters Var Value Output 1 (main) NSx 3.0 Rounded Down NSx Rounded Down Vox
Units Description Secondary Number of Turns Rounded to Integer Secondary Number of Turns Volts Auxiliary Output Voltage for Rounded down to Integer Secondary Number of Turns Rounded to Next Integer Secondary Number of Turns Volts Auxiliary Output Voltage for Rounded up to Next Integer Secondary Number of Turns AWG Secondary Wire Gauge Range
Rounded Up NSx Rounded Up Vox
6 3.70
8 5.10
19 12.60
AWGSx Range
27 - 31
27 - 30
28 - 32
26 - 30
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DER-51
16W STB Power Supply
April 20, 2005
9 Performance Data
All measurements performed at room temperature, 50 Hz input frequency. 9.1 Efficiency
All rails were loaded to full specified power as defined in section 2. Figure 6 below shows the conversion efficiency as a function of input line voltage.
90 85 Efficiency (%) 80 75 70 65 60 180
200
220
240
260
280
Input Voltage (Vrms)
Figure 6- Efficiency vs. Input Voltage
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DER-51 9.2 Regulation
16W STB Power Supply
April 20, 2005
9.2.1 Line
115 Regulation (% of Nominal) 110 105 100 95 90 85 180 -5V Rail 1V8 Rail 3V3 Rail 5V Rail 12V Rail
200
220
240
260
280
Input Voltage (Vrms)
Figure 7 -Load Regulation.
9.2.2 Cross Regulation The defined minimum and maximum loads for the power supply are given in Table 1 below.
Rail Voltage (V) -5 1.8 3.3 5 12 Min Current (A) 0.01 0.3 0.4 0.2 0.01 Max Current (A) 0.01 0.6 0.75 0.52 0.8
Table 1 - Minimum and Maximum Loads
Since realistic load combinations are as yet unknown, cross-regulation results are based on all possible combinations of minimum and maximum load. Table 2 gives the output voltages for each load combination based on the min/max loads given above.
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DER-51
Combination 1V8 - 3V3 - 5V - 12V XXXX XXXM XXMX XXMM XMXX XMXM XMMX XMMM MXXX MXXM MXMX MXMM MMXX MMXM MMMX MMMM Minimum Voltage (V) Maximum Voltage (V) Minimum % of Nominal (%) Maximum % of Nominal (%)
16W STB Power Supply
Rail Voltages 3V3 3.25 3.24 3.27 3.26 3.22 3.23 3.25 3.24 3.25 3.24 3.27 3.26 3.22 3.23 3.24 3.24 3.22 3.27 97.58 99.09
April 20, 2005
-5V -3.92 -4.91 -4.28 -4.88 -4.10 -4.92 -4.85 -4.88 -4.00 -4.90 -4.61 -4.87 -4.33 -4.90 -4.91 -4.89 -4.92 -3.92 98.40 78.40
1V8 1.79 1.82 1.80 1.82 1.81 1.83 1.83 1.84 1.72 1.76 1.74 1.77 1.75 1.78 1.77 1.79 1.72 1.84 95.56 102.22
5V 5.08 5.08 5.02 5.04 5.16 5.14 5.08 5.09 5.09 5.08 5.02 5.04 5.16 5.14 5.08 5.09 5.02 5.16 100.40 103.20
12V 12.47 11.49 12.77 11.56 12.80 11.62 13.10 11.69 12.57 11.50 12.87 11.57 12.94 11.63 13.19 11.70 11.49 13.19 95.75 109.92
Table 2 - Cross Regulation Measurements at 230Vac input
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DER-51
16W STB Power Supply
April 20, 2005
10 Thermal Performance
The operating temperature of key power stage components was measured for full output power as a function of input line voltage. The PCB was mounted horizontally in free air with a recorded lab ambient temperature of 28C. Figure 8 shows the temperature of the TOP243P, the transformer core, the 12V rail output cap and the input 22uF, 400V bulk capacitor.
90 Temperature (Deg C) 80 70 60 50 40 30 20 10 0 180 200 220 240 260 280 12V Rail 220uF, 35V Output Cap Ambient TOP243P Transformer Core 22uF, 400V Bulk Cap
Input Voltage (Vrms)
Figure 8 - Key Component Operating Temperature
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DER-51
16W STB Power Supply
April 20, 2005
11 Waveforms
11.1 Drain Voltage and Current, Steady State Full Power Operation
Figure 9 - 195 VAC, Full Load. Lower: IDRAIN, 0.2 A / div Upper: VDRAIN, 200 V, 5 s / div
Figure 10 - 265 VAC, Full Load Lower: IDRAIN, 0.2 A / div Upper: VDRAIN, 200 V / div
11.2 Drain Voltage and Current Start-up Profile
Figure 11 - 195 VAC Input and Maximum Load. Lower: IDRAIN, 0.2 A / div. Upper: VDRAIN, 200 V & 1 ms / div.
Figure 12 - 265 VAC Input and Maximum Load. Lower: IDRAIN, 0.2 A / div. Upper: VDRAIN, 200 V & 1 ms / div.
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DER-51
16W STB Power Supply
April 20, 2005
11.3 Output Voltage Start-up Profile
Figure 13 - 230 VAC Input and Maximum Load. Upper: 1V8 Voltage, 0.5 V / div. Lower: -5V Voltage, 2 V & 10 ms / div.
Figure 14 - 230 VAC Input and Maximum Load. Upper: 1V8 Voltage, 0.5 V / div. Lower: 3V3 Voltage, 1 V & 10 ms / div.
Figure 15 - 230 VAC Input and Maximum Load. Upper: 1V8 Voltage, 0.5 V / div. Lower: 5V Voltage, 2 V & 10 ms / div.
Figure 16 - 230 VAC Input and Maximum Load. Upper: 1V8 Voltage, 0.5 V / div. Lower: 12V Voltage, 5 V & 10 ms / div.
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DER-51
16W STB Power Supply
April 20, 2005
11.4 Load Transient Response (75% to 100% Load Step) In the figures shown below, signal averaging was used to better enable viewing the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response.
Figure 17 - Transient Response, 230 VAC, 0.4A to 0.75A Current Change on 3V3 output. Top: 3V3 Rail Current, 0.2 A/div. Bottom: AC Coupled 3V3 Rail Output Voltage 50 mV, 5 ms / div.
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DER-51
16W STB Power Supply
April 20, 2005
11.5 Hold-up Time Hold-up time was measured at full power output with 230Vac input. Figure 18 and Figure 19 below show the hold-up is greater than 60ms in worst case.
Figure 18 - Hold-up measured from top of mains cycle. Upper trace is mains voltage at 200V/div and lower trace is 3V3 rail output voltage at 1V/div. Timebase is 20ms/div.
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DER-51
16W STB Power Supply
April 20, 2005
Figure 19- Hold-up measured from center of mains cycle. Upper trace is mains voltage at 200V/div and lower trace is 3V3 rail output voltage at 1V/div. Timebase is 20ms/div.
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DER-51
16W STB Power Supply
April 20, 2005
11.6 Output Ripple Measurements 11.6.1 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 20 and Figure 21. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 20 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 21 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
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DER-51
16W STB Power Supply
April 20, 2005
11.6.2 Measurement Results
Figure 22 - -5V Rail Ripple, 230 VAC, Full Load. 5 ms, 20 mV / div
Figure 23 - 1V8 Rail Ripple, 230 VAC, Full Load. 5 ms, 5 mV / div
Figure 24 - 3V3 Rail Ripple, 230 VAC, Full Load. 5 ms, 5 mV / div
Figure 25 - 5V Rail Ripple, 230 VAC, Full Load. 5 ms, 5 mV / div
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DER-51
16W STB Power Supply
April 20, 2005
Figure 26 - 12V Rail Ripple, 195 VAC, Full Load. 5 ms, 50 mV / div
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DER-51
16W STB Power Supply
April 20, 2005
12 Surge Test Results
Surge tests were performed according to EN61000-4-5 for both differential and commonmode surge. 12.1 Differential Mode Surge Tests The surge equipment guarantees 10% accuracy so the programmed surge level was set 10% higher than the required levels 1kV, 2kV and 3kV to ensure that in worse case the surge level was high enough. Surges were performed at phase angles of 0, 90, 180, 270 and 359 with two strikes of both positive and negative surge. For 1kV, 2kV and 3kV levels, the surge had no effect on the PSU and power was provided continually throughout the duration of the surge. With 4kV surge, the radial fuse (3.15A) was destroyed but the PSU continued to operate when the fuse had been replaced. 12.2 Common Mode Surge Tests Common mode surge voltage of 3.3kV was applied between Live and Earth with phase angles of 0, 90, 180, 270 and 359 with both positive and negative going pulses. Figure 27 below summarizes the results.
Phase Angle Pulse Polarity 0 90 180 270 359
Positive
Strike 1 Normal Operation Strike 2 Normal Operation
Normal Operation Normal Operation Power dropout for about 0.5 second Normal Operation
Normal Operation Normal Operation
Normal Operation
Power dropout for Normal Operation Power dropout for about 0.5 second about 0.5 second Normal Operation Normal Operation Power dropout for about 1 second Normal Operation Normal Operation Normal Operation
Negative
Strike 1 Normal Operation Strike 2 Normal Operation
Figure 27 - Results of Common-Mode Surge Testing
In all cases above, any PSU dropout was followed by full automatic recovery of the power supply.
Page 27 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-51
16W STB Power Supply
April 20, 2005
13 Conducted EMI
The measurements presented below are pre-compliance and should only be used for guidance. Results are presented both with and without the output grounded. Output grounded is indicative of functional grounding through a SCART lead.
Figure 28 - 230VAC input. Full load output with output floating
Figure 29 - 230VAC input. Full load output with output grounded to protective Earth
Page 28 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-51
16W STB Power Supply
April 20, 2005
14 Revision History
Date April 20, 2005 Author IM Revision 1.0 Description & changes Initial release Reviewed VC / JC / AM
Page 29 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-51
16W STB Power Supply
April 20, 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
INDIA (TECHNICAL SUPPORT) Innovatech 261/A, Ground Floor 7th Main, 17th Cross, Sadashivanagar Bangalore, India, 560080 Phone: +91-80-5113-8020 Fax: +91-80-5113-8023 e-mail: indiasales@powerint.com ITALY Via Vittorio Veneto 12, Bresso, Milano, 20091, Italy Phone: +39-028-928-6001 Fax: +39-028-928-6009 e-mail: eurosales@powerint.com
UK (EUROPE & AFRICA HEADQUARTERS) 1st Floor, St. James's House East Street Farnham, Surrey GU9 7TJ United Kingdom Phone: +44-1252-730-140 Fax: +44-1252-727-689 e-mail: eurosales@powerint.com
APPLICATIONS FAX World Wide +1-408-414-9760
Page 30 of 30
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com

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