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Design Example Report
Title Specification Application Author Document Number Date Revision 17.4 W Power Supply using TOP244P Input: 160 - 275 VAC Output: 3.3V/1.0A, 5.1V/1.0A, 9.0V/1.0A Set Top Box Power Integrations Applications Department DER-99 September 12, 2005 1.0
Summary and Features This report describes a prototype design for a Set Top Box using a TOPSwitch-GX TOP244P, featuring: * Self-recovering AC Line Overvoltage shutdown to prevent damage during high voltage swells * Meets 388 VAC swell * Meets 6 kV surge * Low EMI * Small common mode choke * Small Y-cap * A low cost secondary `power good' detection circuit
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-99
Set Top Box 17.4 W Power Supply
September 12, 2005
Table Of Contents
Introduction................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic................................................................................................................... 6 Circuit Description ...................................................................................................... 8 4.1 EMI Filtering ........................................................................................................ 8 4.2 TOPSwitch Primary ............................................................................................. 8 4.3 Power Good signal.............................................................................................. 8 5 PCB Layout ................................................................................................................ 9 6 Bill Of Materials ........................................................................................................ 10 7 Transformer Specification......................................................................................... 12 7.1 Electrical Diagram ............................................................................................. 12 7.2 Electrical Specifications..................................................................................... 12 7.3 Materials............................................................................................................ 12 7.4 Transformer Build Diagram ............................................................................... 13 7.5 Transformer Construction.................................................................................. 14 8 Transformer Spreadsheets....................................................................................... 15 9 Performance Data .................................................................................................... 18 9.1 Efficiency........................................................................................................... 18 9.2 Regulation ......................................................................................................... 18 9.2.1 Cross Regulation........................................................................................ 18 9.3 Thermal Performance........................................................................................ 18 9.4 Surge test.......................................................................................................... 19 9.4.1 Surge Test Setup ....................................................................................... 19 9.4.2 Surge Test Results..................................................................................... 19 9.5 AC Line Over Voltage (388 VAC swell) ............................................................. 20 9.6 Hold-Up Time and Power Good ........................................................................ 21 10 Waveforms............................................................................................................ 23 10.1 Drain Voltage and Current, Normal Operation .................................................. 23 10.2 Drain Voltage and Current Start-up Profile........................................................ 23 10.3 Output Ripple Measurements............................................................................ 24 10.3.1 Ripple Measurement Technique ................................................................ 24 10.3.2 Measurement Results ................................................................................ 25 11 Control Loop Measurements................................................................................. 26 11.1 160 VAC Maximum Load .................................................................................. 26 11.2 230 VAC Maximum Load .................................................................................. 26 12 Conducted EMI ..................................................................................................... 27 13 Revision History.................................................................................................... 28 1 2 3 4
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
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.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 3 of 29
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
1 Introduction
This document is an engineering report describing a Set-top power supply utilizing a TOP244P. 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
Page 4 of 29
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
2 Power Supply Specification
Description Input Voltage Frequency 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 Total Output Power Continuous Output Power Efficiency Full Load Environmental Conducted EMI Safety
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II 100 kHz ring wave, 200 A short circuit current, differential and common mode Free convection, sea level
Symbol VIN fLINE
Min 160 47
Typ 230 50/60
Max 275 63
Units VAC Hz
Comment
2 Wire - no P.E.
VOUT1 VRIPPLE1 IOUT1 VOUT1 VRIPPLE1 IOUT1 VOUT1 VRIPPLE1 IOUT1 POUT
3.135 0.30 4.85 0.020 8.40 0.25
3.30
5.10
9.00
3.465 50 1.00 5.35 50 1.00 9.60 50 1.00 17.4
V mV A V mV A V mV A W %
20 MHz bandwidth
20 MHz bandwidth
20 MHz bandwidth
70
230VAC, 25 oC
Surge Ambient Temperature TAMB
6 65
kV
o
C
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
3 Schematic
Figure 2 - Schematic. Primary Side
Page 6 of 29
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FROM C23
1
C25 R20 C4 1 nF 220 uF
10 V
1
DER-99
51 D13 SB360 C26 100 V R21 51 1 nF D10 SB340 C27 R22
100 V 10 V
10 V 10 V
2
6
220 uF
4
5
100 V
BAV20
1000 uF
U4A PC817A
6.34 k
C24 1 uF
50 V
D14 R19 10
10 V 0.125 W
220 uF
C11 1.0 uF R7 1k U3
0.125 W 50 V
C29
1
47 uF
VR1
5 .1 V
1N5231B
0.125 W
R18 10 k
R27 75 k
0.125 W
D19 2N3904 Q1
R28 22 k
0.1 25 W
R29 4.7 k Q2 2N3904
0.125 W
0 .125 W
1
September 12, 2005
D18 1N4148
1N4148 C30 R30 22 uF 56 k
10 V
Q3 2N3904
CHASSIS G UND RO
Page 7 of 29
L1 3.3 uH C18 1000 uF L2 3.3 uH C21 J1 J2 C19 1000 uF 1 nF 51 D11 C20
0.125 W 10 V
1
TN
9V/1A
T1
8
5V/1A
J3
7
3
SB330
L3 3.3 uH R3 160 C22
3.3V/1A
R4 20 k
1%
1
EE L22
J5 R5
1%
Set Top Box 17.4 W Power Supply
R6 1k
RTN
Figure 3 - Schematic Secondary Side
R14 1k
0.125 W
35 V
TL431
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
R8 10 k
1%
PGF
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
4 Circuit Description
4.1 EMI Filtering L6 and C15 form the main EMI filter. C23 and C14 reduce radiated EMI, and the RC networks across the output diodes also reduce high frequency conducted and radiated EMI. 4.2 TOPSwitch Primary The TOPSwitch has a built-in bulk voltage OVLO (over-voltage lockout) protection. It senses the bulk voltage through R24 and R25. If the bulk voltage exceeds the set threshold, it will shutdown until the voltage falls back to safe levels. This will prevent failure due to Drain over-voltage during an AC voltage swell. 4.3 Power Good signal Q1, Q2, Q3 and associated circuitry form the power-good signal. D14 charges C24 during the on-time of the TOP244P, and form a "forward mode" output. C24 has a negative voltage that is proportional to the bulk capacitor when the TP244P is running. VR1 and Q1 sense when the bulk cap is below a certain threshold. When AC power is removed, the bulk voltage drops and Q1 turns on, rapidly discharging C30, turning off Q2 and turning Q3 on, and the power-good signal output goes low. This bulk voltage threshold, and zener VR1 voltage is chosen so that this happens >5mS before the outputs drop out of regulation when at full load. R27 and C30 form a delay so that at power-up, the power-good signal is delayed >500 mS before it comes up.
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
5 PCB Layout
Figure 4 - Printed Circuit Layout
9Vout 5.1Vout RET 3.3Vout PG
Figure 5 - Silk Screen
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
6 Bill Of Materials
Item Quantity Value Number 1 1 1 nF 2 3 220 uF 3 1 1.0 uF 4 1 100 nF 5 1 22 uF 6 1 10 pF 7 1 100 nF 8 1 47 uF 9 1 4.7 uF 10 3 1000 uF 11 12 13 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 43 1 1 3 1 1 1 4 2 1 1 1 2 1 3 1 3 1 1 1 1 1 3 1 1 1 1 3 1 1 1 1 1 1 Description Part Reference C1 C4 C21 C22 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C23 C24 C25 C26 C27 C29 C30 D3 D4 D5 D7 D8 D9 D14 D10 D11 D13 D18 D19 F1 L1 L2 L3 L6 Q1 Q2 Q3 R1 R2 R3 R4 R5 R6 R7 R14 R8 R10 R18 R19 R20 R21 R22 R23 R24 R25 R27 R28 R29 1 nF, 1 kV, Disc Ceramic 220 uF, 10 V, Electrolytic, Gen. Purpose, (6.3 x 11) 1.0 uF, 50 V, Ceramic, X7R 100 nF, 50 V, Ceramic, X7R 22 uF, 400 V, Electrolytic, Low ESR, 901 mOhm, (16 x 20) 10 pF, 1 kV, Disc Ceramic 100 nF, 275 VAC, Film, X2 47 uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) 4.7 uF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) 1000 uF, 10 V, Electrolytic, Very Low ESR, 38 mOhm, (10 x 16) 47 pF 47 pF, Ceramic, Y1 1 uF 1 uF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) 1 nF 1 nF, 100 V, Ceramic, COG 47 uF 47 uF, 35 V, Electrolytic, Gen. Purpose, (5 x 11) 22 uF 22 uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) 1N4007GP 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 1N4007 1000 V, 1 A, Rectifier, DO-41 BAV20 200 V, 200 mA, Fast Switching, 50 ns, DO-35 SB340 40 V, 3 A, Schottky, DO-201AD SB330 30 V, 3 A, Schottky, DO-201AD SB360 60 V, 3 A, Schottky, DO-201AD 1N4148 75 V, 300 mA, Fast Switching, DO-35 3.15 A 3.15 A, 250V,Fast, TR5 3.3 uH 3.3 uH, 2.66 A 5 mH 5 mH, 0.3 A, Common Mode Choke 2N3904 NPN, Small Signal BJT, 40 V, 0.2 A, TO-92 150 k 150 k, 5%, 1/2 W, Carbon Film 100 100 R, 5%, 1/4 W, Carbon Film 160 160 R, 5%, 1/8 W, Carbon Film 20 k 20 k, 1%, 1/4 W, Metal Film 6.34 k 6.34 k, 1%, 1/4 W, Metal Film 1k 1 k, 5%, 1/8 W, Carbon Film 10 k 10 k, 1%, 1/4 W, Metal Film 6.8 6.8 R, 5%, 1/8 W, Carbon Film 10 k 10 k, 5%, 1/8 W, Carbon Film 10 10 R, 5%, 1/8 W, Carbon Film 51 51 R, 5%, 1/4 W, Carbon Film 330 330 R, 5%, 1/8 W, Carbon Film 910 k 910 k, 5%, 1/4 W, Carbon Film 910 k 910 k, 5%, 1/4 W, Carbon Film 75 k 75 k, 5%, 1/8 W, Carbon Film 22 k 22 k, 5%, 1/8 W, Carbon Film 4.7 k 4.7 k, 5%, 1/8 W, Carbon Film
Page 10 of 29
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DER-99
44 45 46 47 48 49 50 1 1 1 1 1 1 1
Set Top Box 17.4 W Power Supply
56 k 400 Vac EEL22 TL431 PC817A TOP244P 1N5231B 56 k, 5%, 1/8 W, Carbon Film MOV, 400V, 80J, 10 mm, RADIAL Custom Transformer LP=800uH 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92 Opto coupler, 35 V, CTR 80-160%, 4-DIP TOPSwitch-GX, TOP244P, DIP-8B 5.1 V, 5%, 500 mW, DO-35
September 12, 2005
R30 RV1 T1 U3 U4 U5 VR1
Page 11 of 29
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
7 Transformer Specification
7.1 Electrical Diagram
3 8 WD#4 +9V 7 WD#5 +5V 5 WD#6 +3.3V 6
WD#1 Bias
4
NC NC WD#3 Balance Winding 1 1 WD#2 Primary 2
Figure 6 - Transformer Electrical Diagram
7.2
Electrical Specifications
60 second, 60 Hz, from Pins 1,2,3,4 to Pins 5,6,7, 8 Pins 1 to 2, all other windings open, measured at 132 kHz Pins 1 to 2, all other windings open, measured at Pins 1-2, with Pins 5,6,7,8 shorted, measured at 132 kHz. 3000 VAC 800 H, -/+10% 1233 kHz (Min.) 35 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
7.3
Materials
Description 2 Core: PC40EEL22, TDK or equivalent Gapped for AL of 222 nH/T Bobbin: EEL22 Vertical 8 pin Magnet Wire: 29AWG Magnet Wire: 34AWG Magnet Wire: 27AWG Copper Foil: 0.1mm*8.5mm Tape: 3M 44 Polyester Film, 5.5 mils thick, 6 mm wide Tape: 3M 44 Polyester Film, 5.5 mils thick, 3 mm wide Tape: 3M 1298 Polyester Film, 2.0 mils thick, 9 mm wide Tape: 3M 1298 Polyester Film, 2.0 mils thick, 18mm wide Varnish
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11]
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
7.4
Transformer Build Diagram
PINS Side
PIN 6 PIN 5 PIN 5 PIN 7 PIN 7 PIN 8 PIN 1 PIN 1 Primary Winding PIN 2 PIN 4 PIN 3 9 Turns 9 Turns 5V Winding 3.3V Winding These windings should be in a single layed
9V Winding
Balance Winding
Bias Winding
6mm Margin
3mm Margin
Figure 7 - Transformer Build Diagram
Copper Foil Wrapped in Tape
Starting lead to be connected to pin 1
Figure 8 - Copper foil preparation for winding #3
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
7.5
Transformer Construction
Bobbin Orientation Safety Margin Place bobbin, item [2] with the pin side oriented to the left hand side Wind margin tape, item [7] on the pin side of the bobbin. Also wind margin tape, item [8] on the top side of the bobbin. Match the height of the tape with the height of the primary side windings. Start at Pin3. Wind 9 turns of item [3] from left to right. Bring the wire lead out and connect it to pin 4. Then bring the wire lead back to the winding area to continue winding 9 more turns from left to right on the same layer. The layer should be uniformly covering the whole winding area. Cut the finish lead at the end of the winding. 1 layer of item [9] for basic insulation. Start at pin 2, wind 20 turns of item [4] from left to right. Distribute the 20 turns uniformly scattered on the whole winding area. Add two layers of tape, item [9]. Wind 40 more turns on a second layer from right to left. Wind tightly and uniformly across whole layer. Finish on pin 1 1 layer of item [9] for basic insulation. Start on pin 1 using item [6] as shown in figure 7. Start at pin 1. Wind 2 turns in reverse winding direction. Finish lead is not connected. Use 3 layers of item [10] for basic insulation Wind margin tape, item [7] on the pin side of the bobbin. Also wind margin tape, item [8] on the top side of the bobbin. Match the height of the tape with the height of the secondary side windings. Wind secondary winding in Normal winding direction. The three windings should be wound in a single layer scattered along the winding area. 9V Winding. Two trifilar turns of item [5] from left to right. Start at pin 8, finish at pin 7 5V Winding. One trifilar turn of item [5] from left to right. Start at pin 7, finish at pin 5 3.3 V Winding. Two trifilar turns of item [5] from left to right. Start at pin 5, finish at pin 6 Apply 3 layer item [10] Assemble and secure core halves [1] with bobbin [2] Varnish impregnate item [11]
Bias Winding
Tape Primary Basic Insulation Balance Winding Insulation Safety Margin
9V, 5V and 3V3 Winding
Insulation Final Assembly
Page 14 of 29
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
8 Transformer Spreadsheets
ACDC_TOPSwitchGX_032 INPUT INFO 204; Rev.1.9; Copyright Power Integrations Inc. 2004 ENTER APPLICATION VARIABLES VACMIN 160 VACMAX 275 fL 50 VO 5 PO 17.4 n 0.72 Z 0.5 VB 15 tC 3 CIN 22 INFO OUTP OUTP UNIT UT UT TOP_GX_FX_032204.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet
Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Volts Bias Voltage mSeco Bridge Rectifier Conduction Time Estimate nds uFarad Input Filter Capacitor s Volts Volts Hertz Volts Watts
ENTER TOPSWITCH-GX VARIABLES TOP-GX TOP24 Univer 115 Doubled/230V 3 sal Chosen Device TOP24 TOP24 Power Power 30W 45W 3 3 Out Out KI 1 External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) ILIMITMIN 0.837 0.837 Amps Use 1% resistor in setting external ILIMIT ILIMITMAX 0.963 0.963 Amps Use 1% resistor in setting external ILIMIT Frequency (F)=132kHz, F Full (F) frequency option - 132kHz (H)=66kHz fS 13200 13200 Hertz TOPSwitch-GX Switching Frequency: Choose between 132 0 0 kHz and 66 kHz fSmin 12400 12400 Hertz TOPSwitch-GX Minimum Switching Frequency 0 0 fSmax 14000 14000 Hertz TOPSwitch-GX Maximum Switching Frequency 0 0 VOR 110 Volts Reflected Output Voltage VDS 10 Volts TOPSwitch on-state Drain to Source Voltage VD 0.5 Volts Output Winding Diode Forward Voltage Drop VDB 0.7 Volts Bias Winding Diode Forward Voltage Drop KP 0.9632 Ripple to Peak Current Ratio (0.4 < KRP < 1.0 : 1.0< 6036 KDP<6.0) ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EEL22 Core EEL22 EEL22 Bobbin EEL22 EEL22_BOBBI _BOB N BIN AE 0.358 0.358 LE 6.32 6.32 AL 1400 1400 BW 18 18 M 4.5 L NS DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE 1.5 3
P/N: P/N:
PC40EE22/29/6-Z *
cm^2 cm nH/T^2 mm mm
Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns
189 389
189 Volts 389 Volts
Minimum DC Input Voltage Maximum DC Input Voltage
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DER-99
PARAMETERS DMAX IAVG IP IR IRMS
Set Top Box 17.4 W Power Supply
September 12, 2005
0.38 0.13 0.65 0.62 0.23
0.38 0.13 0.65 0.62 0.23
Amps Amps Amps 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 ur LG BWE OD INS DIA AWG CM CMA
800 60 9 222 2412 3587 1162 1967 0.17 13.5 0.23 0.04 0.18 34 40 172
800 uHenri es 60 9 222 nH/T^2 2412 Gauss 3587 Gauss 1162 Gauss 1967 0.17 mm 13.5 mm 0.23 mm 0.04 mm 0.18 mm 34 AWG
Primary Inductance
Warnin Warnin g g
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) 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) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) 40 Cmils Bare conductor effective area in circular mils 172 Cmils/ !!!!!!!!!! INCREASE CMA>200 (increase L(primary Amp layers),decrease NS,larger Core)
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 12.96 12.96 Amps Peak Secondary Current ISRMS 6.00 6.00 Amps Secondary RMS Current IO 3.48 3.48 Amps Power Supply Output Current IRIPPLE 4.89 4.89 Amps Output Capacitor RMS Ripple Current CMS AWGS DIAS ODS INSS VOLTAGE STRESS PARAMETERS VDRAIN PIVS PIVB 1200 19 0.91 3.00 1.04 1200 Cmils 19 AWG 0.91 mm 3.00 mm 1.04 mm Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness
640 24 71
640 Volts 24 Volts 71 Volts
Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 5.1 Volts Output Voltage IO1 1.000 Amps Output DC Current PO1 5.10 5.10 Watts Output Power VD1 0.5 Volts Output Diode Forward Voltage Drop NS1 3.05 3.05 Output Winding Number of Turns ISRMS1 1.724 1.724 Amps Output Winding RMS Current IRIPPLE1 1.40 1.40 Amps Output Capacitor RMS Ripple Current PIVS1 25 25 Volts Output Rectifier Maximum Peak Inverse Voltage Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 16 of 29
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
CMS1 AWGS1 DIAS1 ODS1 2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 CMS2 AWGS2 DIAS2 ODS2 3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 CMS3 AWGS3 DIAS3 ODS3 Total power
345 24 0.51 2.95
345 Cmils 24 AWG 0.51 mm 2.95 mm
Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
3.3 1.000 3.30 0.5 2.07 1.724 1.40 17 345 24 0.51 4.34
Volts Amps 3.30 Watts Volts 2.07 1.724 Amps 1.40 Amps 17 Volts 345 Cmils 24 AWG 0.51 mm 4.34 mm
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
9.0 1.000 9.00 0.5 5.18 1.724 1.40 43 345 24 0.51 1.74 17.4
Volts Amps 9.00 Watts Volts 5.18 1.724 Amps 1.40 Amps 43 Volts 345 Cmils 24 AWG 0.51 mm 1.74 mm 17.4 Watts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Total Power for Multi-output section
Page 17 of 29
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency
VIN (AC) Input Power (W) Total PO (W) Output Efficiency (%) 160 21.7 17.11 78.85 230 21.8 17.11 78.49 Figure 9 - Efficiency Data. Each Output is loaded at 1.0Amp. Room Temperature, 60 Hz.
9.2
Regulation
9.2.1 Cross Regulation
VIN (AC) ____OUT LOAD (ADC)______ ___MEASURED OUTPUT VOLTAGE (DC) 3.3 V 5V 9V 3.3 V 5V 9V
(3.135--3.465)
(4.85--5.35) 5.21 5.20 5.00 5.02 5.42 5.32 5.12 5.11 4.85--5.35 5.21 5.20 5.00 5.01 5.43 5.32 5.12 5.11 (8.40--9.60) 8.70 8.40 8.93 8.58 9.07 8.59 9.21 8.74 8.40--9.60 8.69 8.39 8.93 8.58 9.08 8.58 9.20 8.74
160VAC
0.300 0.300 0.300 0.300 1.000 1.000 1.000 1.000
0.020 0.020 1.000 1.000 0.020 0.020 1.000 1.000
0.250 1.000 0.250 1.000 0.250 1.000 0.250 1.000
3.23 3.23 3.29 3.28 3.16 3.19 3.25 3.26
230VAC
0.300 0.300 0.300 0.300 1.000 1.000 1.000 1.000 0.020 0.020 1.000 1.000 0.020 0.020 1.000 1.000 0.250 1.000 0.250 1.000 0.250 1.000 0.250 1.000
3.135--3.465
3.23 3.23 3.29 3.28 3.15 3.19 3.25 3.26
Figure 10 - Cross Load Regulation, Room Temperature
9.3 Thermal Performance The power supply was tested under the following conditions. Vin (AC) Load Ambient Temperature (oC )
160 275 Full Load Full Load 75 o 75
o
Figure 11 - Thermal Test Conditions
The supply operated for several hours at 75oC without going into thermal shut down. This implies very good margin against the max 65oC specification
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
9.4
Surge test
9.4.1 Surge Test Setup The unit was tested against spec IEEE-587. The figure below shows the waveform for the high voltage surge.
Figure 12 - Ring Waveform
Test Conditions
Vpeak Test Voltage Test Current Polarity Phase Test Mode Interval Between Tests 6KV 200A +/0,90,180,270 Differential Mode (L-N) and Common Mode (L1,N---GND). 1 minute.
9.4.2 Surge Test Results. The unit passes 6 KV in Both Differential and Common Mode
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
9.5
AC Line Over Voltage (388 VAC swell)
Figure 13 - AC Line Over-voltage. Top Trace is the input bulk capacitor Voltage (100 V / Div). Bottom trace is the DRAIN Voltage (200 V / Div).
The AC Line voltage was slowly increased to 388 VAC. When this voltage reached 313 VAC (443 Vdc on bulk cap, top trace of above figure), the TOPSwitch shuts down and the supply stops running. When the AC Line is lowered to nominal voltage, the supply starts to run again. Just before the point of shutdown, the Drain voltage of the TOP244P reaches a maximum of 620 V, which is far below the max rating of 700 V.
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DER-99 9.6
Set Top Box 17.4 W Power Supply
September 12, 2005
Hold-Up Time and Power Good
Figure 14 - Hold-Up time. At Full Output Load. Top Trace is the AC Line Voltage, Middle trace 5V output, Bottom Trace is the HV DC bus. AC voltage is 160 Vac.
Note: The AC line was interrupted for about 28ms. The power supply maintained output regulation for the whole time the AC line was off.
AC Off
Power good
3V output
Figure 15 - 10mS/div. Holdup and power good. 160Vac, full load. Notes: * 3V output drops out >20 mS after AC turns off. (Spec is >16.7 mS) * Power good goes down 10 mS before 3V (Spec is > 5mS) * 160Vac is the worst case. Higher voltages show even greater holdup time.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 21 of 29
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
Figure 16 - Power up sequence of Powergood signal. 200 mS/div
Note: Power good comes up 600 mS after 3 V comes into regulation (Spec is >500 mS)
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Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
10 Waveforms
10.1 Drain Voltage and Current, Normal Operation
Figure 17 - 160 VAC, Full Load Upper: IDRAIN, 0.5 A / div Lower: VDRAIN, 200 V, 2 s / div
Figure 18 - 275 VAC, Full Load Upper: IDRAIN, 0.5 A / div Lower: VDRAIN, 200 V / div
10.2 Drain Voltage and Current Start-up Profile
Figure 19 - 160 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 200 V & 2 us / div.
Figure 20 - 275 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 200 V & 2 us / div.
Page 23 of 29
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
10.3 Output Ripple Measurements 10.3.1 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 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 21 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 22 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
Page 24 of 29
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
10.3.2 Measurement Results
Figure 23 - 9 Voutput Ripple, 160 VAC, Full Load. 10 ms, 50 mV / div
Figure 24 - 5 Voutput Ripple, 160 VAC, Full Load. 10 ms, 50 mV / div
Figure 25 - 3.3 Voutput Ripple, 160 VAC, Full Load. 10 ms, 50 mV /div
Page 25 of 29
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DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
11 Control Loop Measurements
These results show phase margin > 60o 11.1 160 VAC Maximum Load
Figure 26 - Gain-Phase Plot, 160 VAC, Maximum Steady State Load Vertical Scale: Gain = 10 dB/div, Phase = 30 /div. Crossover Frequency = 2.557 kHz Phase Margin = 89
11.2 230 VAC Maximum Load
Figure 27 - Gain-Phase Plot, 230 VAC, Maximum Steady State Load Vertical Scale: Gain = 10 dB/div, Phase = 30 /div. Crossover Frequency = 1.953 Hz, Phase Margin = 95
Page 26 of 29
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
12 Conducted EMI
Figure 28 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits. Supply is at full load. OUTPUT RETURN connecter to Chassis Ground
Page 27 of 29
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-99
Set Top Box 17.4 W Power Supply
September 12, 2005
13 Revision History
Date September 12, 2005 Author VC Revision 1.0 Description & changes First Release Reviewed VC / AM
Page 28 of 29
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-99
Set Top Box 17.4 W Power Supply
September 12, 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 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 HOTLINE APPLICATIONS FAX 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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