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title engin eerin g proto t ype rep o rt (ep-21) ? 30 w dc- dc c o nverter wit h dp a424 specific a tio n 36 vdc to 7 2 vd c input, 5 v @ 6 a output a p p lic ati on tel e c o m au t h o r pi applications d epartment docu me nt num b er EPR-21 date 19-nov-0 2 re v i sio n 4.0 feat ures ver y low c o mpon ent c ount ? ? ? ? ? ? hig h eff i cie n cy ? n o cur r ent s ense co m pon ents ? integ r ate d m o sfe t d e si g ned f o r v e r y l o w s w i t chi n g and g a te dr i v e l o sses ? 85% w i th low cost s.b. d. r e ctif i e r d pa- swi t c h in teg r ates : ? accur a te l i ne o v a nd ov shu t dow n ? t h er mal pr otec ti on ? ov er l oad an d o pen l o o p f a ul t pr ot ecti o n ? re gu la tio n at z e ro lo ad (cy c le skip p i n g ) ? 400 khz trim med i n ter nal oscillator n o h eat si nk or d e r a ti ng at u p to 55 c t e s t ed ov er indus tr i a l t e mp er atur e r ang e ( - 40 c t o 85 c) h i g h bandw i d th ( 6 kh z ) pow e r integrations, inc. 5245 he ll y e r av enu e, san j o s e , ca 951 38 u s a. app lic at io ns hot l i ne: t e l: + 1 40 8 41 4 9 660 f a x : +1 4 08 4 14 9 760 www.po weri nt.c om
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 tabl e of contents 1 intr od uction ................................................................................................................. 3 2 pow e r suppl y speci f i c ati o n ........................................................................................4 3 sche matic ...................................................................................................................5 4 cir cuit de scr iption .......................................................................................................6 4.1 pr imar y cir cuitry ......................................................................................................6 4.2 outp ut recti f ic ation .................................................................................................6 4.3 outp ut fe edb ack .....................................................................................................7 4.4 constr uctio n ............................................................................................................7 5 pcb lay out .................................................................................................................8 6 bill of m a terials ...........................................................................................................9 t r ans for m e r sp eci f icat ion ................................................................................................10 7.1 electr ical sp eci f ication s .........................................................................................10 7.2 m a ter i als ................................................................................................................10 7.3 t r ans for m e r build dia g r am ...................................................................................11 7.4 t r ans for m e r constr uc tion ......................................................................................11 8 induc tor s peci f i c ati o n ................................................................................................12 8.1 electr ical sp eci f ication s .........................................................................................12 8.2 m a ter i als ................................................................................................................12 8.3 induc tor b u i l d d i a g r am ..........................................................................................13 8.4 induc tor c ons tr ucti on ............................................................................................13 9 pix l s d e si g n spr eads heet ........................................................................................14 10 per f or m ance data .....................................................................................................17 10.1 e f f i ciency ...........................................................................................................17 10.2 reg u lation .........................................................................................................18 10.2 . 1 loa d reg u latio n .............................................................................................18 10.2 . 2 line reg u lati on ..............................................................................................18 11 t h er mal per f or ma nce ...............................................................................................19 12 w a v e for m s ................................................................................................................21 12.1 dr ain voltag e and cur r ent, n o r m al oper a t ion ...................................................21 12.2 outp ut v o ltag e s t ar t- u p pr o f ile ..........................................................................22 12.3 loa d t r ansie nt res p o n se ( 7 5 % to 10 0% l o a d ste p ) ........................................23 12.4 outp ut ripple m eas ur eme n ts ............................................................................24 12.4 . 1 ripple m eas ur em ent techniq u e ....................................................................24 12.4 . 2 m easur e m en t results ....................................................................................25 13 contr o l l oop m easur e m en ts .....................................................................................26 13.1 m a x i mum l oad 36 vd c .....................................................................................26 13.2 m a x i mum l oad 48 vd c .....................................................................................26 13.3 m a x i mum l oad 72 vd c .....................................................................................27 14 rev i sion histor y ........................................................................................................28 important note: a l t houg h the ep- 2 1 i s desi g ned t o sa ti s f y tel e com s a f e ty i s ol ati o n r e q u i r ements, thi s eng i neer i n g pr ot oty pe has n o t bee n ag ency a ppr ov ed. p a ge 2 of 32 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 1 i n tr oducti on t h i s doc u m en t i s an eng i neer i n g r epor t desc r i b i n g a 5 v, 30 w d c - d c conv er ter uti l i z i n g th e dpa 4 24 r. t h is doc u m ent co ntai ns the pow er supply specif ic ation, sch e m atic, bill of materials, tr ans f o r m er d o cu me nt ati on, pr i n te d ci r c ui t l a y out, an d p e r f or m ance data . figur e 1 ?
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 2 po w e r suppl y s p e c i f icati on de s c r i ption sy mbol mi n ty p m ax units comment input input vo lta ge v in 3 6 4 8 7 2 v d c input vo lta ge uv t u r n - o n 3 6 v d c s ee a n -31 input vo lta ge uv t u r n - o ff 29 vdc s ee a n -31 input vo lta ge o v t u r n - o ff 75 90 vdc s ee a n -31 input vo lta ge o v t u r n - o n 72 vdc s ee a n -31 output o u tput vo lta ge v ou t 4 . 8 5 5 . 2 v
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 3 schematic figur e 2 ?
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 4 ci r c ui t desc r i pti o n 4.1 primar y c i rcuit r y t h e sche m a t i c i n fi g u r e 2 show s a si ng l e - ende d f o r w ar d conv er ter usi n g the d pa4 24r . t h e ci r c ui t i s desi g ned for 36 v to 72 v i nput r ang e and 5 v, 6 a output . c 1 and l1 pr ov i de i nput f i l t er i n g . c 2 and c 3 by pass the d c r a i l . t he d c r a i l i s appl i ed t o th e pr i m ar y w i ndi ng of t1. t h e o t her si d e o f t he tr ans for m er pr i m ar y i s dr i v en by the i n teg r ate d m o sfet i n u 1 . c 8 r educes t he am pl i t ud e o f l eak ag e spi k es g ener ate d w hen the m o sfet in u1 sw itches o ff. vr 1 cla m ps the u1 dr ain v o ltag e to a sa f e v a lue dur ing faul t condi ti o n s, b u t i s i n acti v e dur i n g nor mal oper ati on. r 1 i s used to set the l o w l i ne tur n - on thr e sh ol d to appr ox i m at el y 33 v, and al so sets th e ov erv o l t ag e shutdow n l e v e l to appr ox i m atel y 88 v. r 3 sets th e u 1 cur r ent l i m i t t o appr ox i m at el y 85% o f i t s no mi nal v a l ue, l i m i t i n g the out put pow er del i v er ed dur i n g f a ul t condi ti o n s. c 5 by passes the u 1 c o n t r o l pi n, a nd pr ov i des the p eak cur r e n t nec essar y for dr i v i n g the d pa- swi t ch i n ter n al m o sfe t . c 6 has thr e e f u nct i ons. it pr ov i d es th e ener g y r e q u i r ed by u 1 dur i n g star tu p, s e ts th e a u to- r e st ar t fr eq uency dur i n g f a ul t condi ti o n s, a nd al so r e duces t he g a i n o f u 1 as a f u ncti on o f f r eq ue ncy . r 4 adds a z e r o to sta b iliz e the p o w e r supply control lo op. 4.2 out put r ect if icat ion t h e out put o f t1 i s r e cti f i e d an d f i l t er ed by d 2 , l2, c 1 0 , an d c 11. t h i s i s the l o w e st cost re ctif icatio n sc h e m e . d pa- swi t c h i s how ever ful l y compati b l e w i th si m p l e sel f - d r i v e n sy nchr onous r e cti f i c ati on sch em es as desc r i bed i n t he dpa - sw itch d a tas hee t. c12 pr ov i des addi ti o nal hi g h f r eq uency f i l t er i n g , a nd i s l o cat ed cl ose t o t h e ou tpu t ter m i nal s o f the s u p p l y . c 7 pr ov i d e s by passi ng f o r hi g h f r eq uency com m on- m o d e n o i s e c o upl e d f r om the pr i m ar y to th e sec ond ar y of t 1 . r 14 da mps pr i m ar y - to- s econ dar y ci r c ul ati n g cur r ent, w h i c h w oul d oth e r w i s e app ear i m pos ed on t h e ou tpu t r i ppl e v o l t ag e. c 9 and r 5 pr ov i de so me sn ubbi ng to d 2 , bu t thei r mai n pur pos e i s to r e set t 1 d u r i ng the u 1 off ti me. d u r i ng the u 1 off ti me, m a g neti z i ng ener gy stor ed i n t he t1 pr i m ar y dur i n g on ti m e i s coupl e d to t he seco ndar y , and ch a r g e s c 9 . t he v o l t ag e on c 9 i s a 1/2 si nusoi d w i th a per i od deter mi n ed by c 9 and the r e f l ected pr i m ar y i n ducta nce o f t1. c 9 i s siz ed such tha t the v o l t ag e g ener at ed d u r i ng the o ff ti me i s su ff i c i ent t o r e s e t t1 be for e th e nex t sw i t chi ng c y cl e occur s . r 5 pr ov i des dampi n g f o r c 9 to pr ev ent hi g h f r eq uency r i ng i n g d u r in g sw itch in g tra n s itio n s . u1 is p o w e r e d d u r ing n o r m a l o p e r a t ion by a n a u x ilia r y f l y b a ck w i n d i n g o n l 2 . th is w i ndi ng del i v er s ener gy dur i n g the o ff ti me o f u 1 , w i th an o u tp ut v o l t ag e pr o por ti o nal t o th e s u pp ly o u t pu t v o lt a g e . t h e t u rn s ra ti o of l 2 sets t h e o u t p u t v o lta g e of t h e a u x ilia ry w i nding to approx im at ely 12 v. d1 an d c4 r e cti f y and f ilt er the aux iliary winding outp u t. p a ge 6 of 32 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter r 13 a ppl i e s a s m al l a m ou nt o f pr el oa di ng to the sup p l y outp ut t o pr ev ent th e v o l t ag e at the aux iliary w i nding o f l 1 f r o m collapsing at z e ro load. r13 is set to prov ide a m i nim u m o f 8 v a t th e ca tho de o f d 1 at z e r o l oad. 4.3 out put feedback r 10 and r 1 1 di v i de dow n the suppl y outpu t v o l t ag e and appl y i t to the r e fer ence pi n o f er r o r ampl i f i e r u 3 . u 3 dr i v es optoco upl er u 2 thr oug h r e si st or r 6 to pr ov i de feed back i n for m a ti on to t he c o n t r o l pi n o f u 1 . th e op toco upl e r outp u t al so pr ov i des p o w e r to u 1 dur i n g nor m a l o per ati n g con d i t i ons . d 3 a nd c 1 3 appl y dr i v e to t he opt ocou pl er d u r i ng suppl y star tu p to el i m i nate ou tpu t v o l t ag e o v er shoot. d 3 i s ol ates c 13 f r o m t h e sup p l y feed back loo p a fter s t ar tup. r7 dischar g e s c 13 w hen the su pply is o ff. r8 pr ov ides bias cur r ent t o u3. c 6 , c 14, c 1 6 , r 4 , r 6 , r 9 , an d r 12 al l pl ay a r o l e i n compe n s a ti ng the p o w e r suppl y contr o l l oop . c 6 r o l l s o f f th e g a i n o f u 1 at a r e l a ti v e ly l o w f r eq uenc y . r 4 pr ov i des a z e r o to cancel th e ph ase sh i f t o f c 6 . r 6 sets the g a i n o f th e di r e ct si g nal path f r o m th e sup p l y outp u t thr oug h u 2 an d u 3 . c 1 4 an d r 9 r o l l o f f the g a i n o f u 3 . r 12 a nd c 1 6 pr ov i d e phas e bo ost n ear th e outp u t f i l t er ( l 2, c 1 0 - 11) r e sona nt f r eq ue n c y to i m pr ov e phas e m a rgin a n d stab ility . 4.4 construction t h e ep 21 i s c onstr uc t ed w i th sur f ace m oun t comp on ents usi n g an al umi n um cl ad ci r c ui t boar d. t h e pr i n te d ci r c ui t bo ar d i s a n e ffecti v e he at s p r ead er , a nd a l l o w s attachm e nt o f a heat si nk o n t he b a ck o f th e b oar d for o per ati on a t hi g h a m bi ent te m per atur e. t a ntal um and c e r a mi c cap a ci tor s ar e us ed i n s t ea d o f c onv enti on al el ectr ol y t i c capaci t or s to en abl e oper ati on at ex tr em e a m bi e n t t e m per at ur es. p a ge 7 of 32 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w. p o we r i n t . c om
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 5 pcb la y out figur e 3 ? ep - 2 1 p r in t e d ci r c u i t lay ou t . p a ge 8 of 32 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 6 bill of m a te rials ep- 21 30 w 4 00 kh z d c - d c bill of m a t e ri als item q t y r e feren c e d e scri p ti on p/n m anufacturer 1 3 c 1 -3 1 ? ? ? ? ? ? ? ? ? ? ? ?
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 7 t r ansform e r s p ecificat ion 4 w d g #2 4 t 4 x #2 7 a w g w d g #1 8 t #27 a w g 3 w d g #3 7 t # 27 a w g 7, 8 1 5, 6 figur e 4 ? e p - 2 1 t r ans f o r m er . 7.1 elect ri cal spec if icat i ons elect rica l st ren g t h 1 s , f r o m pins 1- 4 t o p i ns 5 - 8 1500 vd c creep ag e bet w een p i ns 1- 4 and p i ns 5- 8 n/a p r im a r y induc ta nc e pins 1- 4, a l l oth e r w i nd ings open , m eas ur ed at 100 k h z , 400 m v rms 450 7.2 m a t e rials it e m d e s c rip t io n [1 ] cor e : pr 1 4 x 8 u nga ppe d n87 mater i a l e p c o s p/n b 6575 5- j - r87 [2 ] bob b i n : 8 pi n p 140 8 s u r f ac e m ount b &b b- 09 6 or equ iv ale n t [3 ] magn et w i r e : #27 a w g d oub le c oate d [4 ] t ape, po l y es ter , 3 m # 129 8 or equ i v . 4. 5 m m w i de [5 ] var n is h p a ge 1 0 of 3 2 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 7.3 transformer build di agram ? pr im ar y sec o n dar y 5, 6 3 7, 8 1 3 4 t ape ? pr im ar y figur e 5 ? ep- 21 t r ans f o r m er build d i a g r a m . 7.4 transformer constru c tion ? p r im a r y star t at p i n 4. w i nd 8 tur n s of item [3] in 1 l a y e r . f i nis h on pi n 3. basic in su lat i o n us e one la y e r of item [4] f o r bas ic ins u la tio n . s e c onda ry winding star t at p i ns 5 an d 6. w i nd 4 qu adr if il ar tur n s of it em [3]. f i n i s h o n p i ns 7 an d 8. basic in su lat i o n us e one la y e r of item [4] f o r bas ic ins u la tio n . ? p r im a r y star t at p i n 3. w i nd 7 tur n s of item [3] in 1 l a y e r . f i nis h on pi n 1. oute r wr a p w r ap w i n d i ngs w i th 3 la y e r s of tape i t em [4]. fina l a s s e m bl y as s e m b le and s e c u r e c o r e hal ves . var n is h im pr egnat e it em [5]. pag e 11 o f 32 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w. p o we r i n t . c om
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 8 i nductor s p ec i f i c a t i on w d g # 2 7 t 2 x #24 a w g w d g # 1 1 8 t #32 a w g 2 1 5, 6 7, 8 figur e 6 ? e p - 2 1 ind u c t or , l2 re v. 6. 8.1 elect ri cal spec if icat i ons elect rica l st ren g t h 1 s , f r o m pins 1, 2 to p i ns 5 - 8 1500 vd c creep ag e bet w een p i ns 1, 2 a nd pi ns 5- 8 n/a induc ta nc e pins 5, 6 to 7 , 8, al l ot her wind ings ope n, m eas ur ed at 100 k h z , 400 m v rms 8 8.2 m a t e rials it e m d e s c rip t io n [1 ] cor e : pr 1 4 x 8 epc o s n8 7, p/ n b 657 55- j - r87 g a p f o r a l of 16 3 n h /t 2 [2 ] bob b i n : 8 pi n p 140 8 s u r f ac e m ount b &b b- 09 6 or equ iv ale n t [3 ] magn et w i r e : #24 a w g d oub le c oate d [4 ] magn et w i r e : #32 a w g d oub le c oate d [5 ] t ape, po l y es ter , 3 m # 129 8 or equ i v . 4. 5 m m w i de [6 ] var n is h p a ge 1 2 of 3 2 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 8.3 inductor build diagra m figur e 7 ? e p - 2 1 ind u c t or cons tr uc ti on. 8.4 inductor construction winding # 1 star t at p i n 1. w i nd 18 t u r n s of item [4] in appr ox im atel y 1 la y e r . f i n i s h on p i n 2 . basic in su lat i o n us e one la y e r of item [5] f o r bas ic ins u la tio n . winding # 2 star t at p i ns 7 an d 8. w i nd 7 bif i lar tur n s of item [3]. f i nis h o n p i ns 5 an d 6. oute r wr a p w r ap w i n d i ngs w i th 3 la y e r s of tape i t em [5]. fina l a s s e m bl y as s e m b le and s e c u r e c o r e hal ves . var n is h im pr egna te item [6]. pag e 13 o f 32 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w. p o we r i n t . c om
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 9 pix l s des i gn s p re adsheet dcdc_dp a fw d_rev1. 02_061802 c o p y right po wer int e grat io ns i n c. 2002 i n p u t i n f o o u tp u t u n i t dp a _061802_ r102xl s: dp a - s w i t ch for w a rd t r ansf or m e r d esi gn s p readsheet out p ut v o l t a g e a n d curr e n t e p 21 dc-dc converter v m a i n 5 v o l t s m a i n out put vol t age i m a i n 6 a m p s m a i n out put c u rrent v o u t 2 v o l t s out put 2 vol t a g e i o u t 2 a m p s out put 2 c u rrent po u t 30 w a t t s tot a l ou t put pow er v b i a s 1 2 . 0 v o l t s dc bi as vol t age f r o m out pu t i ndu c t or w i ndi ng i n p u t v o l t a ge a n d uv / o v v m i n 36 dc vol t s m i ni m u m dc i npu t vol t age v m a x 72 dc vol t s m a x i m u m dc i nput vol t age min m a x vu v o ff 30 30. 0 33. 1 d c vol t s m i ni m u m undervol t age on-o f f t h res hol d v u v on 32. 2 34. 6 d c vol t s m a x i m u m undervol t age of f - on t h res hol d (t urn-on) vo v o n 74. 8 - dc vol t s m i ni m u m overvol t age of f - on t h reshol d vo v o ff - 9 4 . 6 d c vo lt s m a x i m u m overvol t age on-of f t h re s hol d (t urn-of f ) r l 618. 0 k oh m li ne s ens e res i st or val ue (l-pi n ) - goal s eek (v uv of f) f o r st d 1 % resi st or se r i e s en t e r d p a - sw it c h v a r i a b le s dp a - s w i t c h d p a 4 2 4 16v d c 3 6 v d c chos en dev i c e dp a 424 p o w e r 15. 5 w 35 w il im it 2. 3 2 2 . 6 8 a m p s f r o m dp a - s w i t c h dat a s heet frequenc y - (f)=400k hz, (l)=300k hz f ful l (f) f r equenc y opt i on - 400 k h z fs 3 7 5 0 0 0 4 2 5 0 0 0 4 0 0 0 0 0 hert z f r o m dp a - s w i t c h dat a s heet k i 1 e x t e rnal l i m i t reduct i on f a ct or (k i = 1. 0 fo r d e f a u l t il im it , ki < 1 .0 fo r lo w e r il im it) i l i m i t e x t 2. 32 a m p s e x t e rnal c u rrent l i m i t rx - k o h m current li m i t res i st or val ue (x -pi n ) - as s u m e s m i ni m u m dat a s heet c u rve (f i g 32) duv o n go a l 0. 71 m a x i m u m al l o w ed dut y c ycl e at v u v on m i n undervol t age t h res h o l d kd i 0. 15 m a x i m u m c u rrent ri ppl e f a c t or vd s 2 v o l t s dp a - s w i t c h average on-s t a t e drai n t o s ourc e v o l t age vd so p 178. 7 vo lt s requi red drai n vol t age f o r guarant eed t r ans f o r m er res e t di ode v f s e l e ct i o n vd m a in 0 . 5 v ol t s m a i n out put di ode s f o rw ard vol t ag e drop vd o u t2 0. 5 v ol t s s e c ondary out put di odes f o rw ard p a ge 1 4 of 3 2 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter vol t age drop vd b 0. 7 v ol t s b i as di ode f o rw ard vol t age drop t r a n s f orm e r core se l e ct i o n core ty pe pr14x8 core p r 14x 8 p / n: b 65755-j - r 8 7 b obbi n p r 14x 8_b o p / n: b 65542-b - t 1 ae 0. 253 cm ^ 2 core e f f e ct i v e cross s e ct i onal a r ea le 2. 53 cm core e f f e ct i v e p a t h lengt h al 2000 nh/ t ^ 2 ungapped core e f f e c t i v e i nduct a n c e bw 4. 4 m m b obbi n p h y s i c al w i ndi ng w i dt h lg m a x 0. 005 0 . 005 m m m a x i m u m act ual gap w hen zero gap s pec i f i ed d f a ct or 1. 00 dut y c ycl e f a ct or l 1 . 10 trans f o r m er pri m ary l a yers ( s pl i t pri m ary re c o m m ended) nm a i n 4 m ai n rounded t u rns ns 2 0 v out 2 rounded s e c ondary t u rn s (a c s t a c k e d w i ndi ng) v o ut2 a c tua l 0. 0 v ol t s a pprox i m at e ou t put 2 vol t age of w i t h ns 2 = 0 t u rns (a c st ack ed s e c ondary) t r a n s f orme r de s i gn p a r a me t e rs np 15 p r i m ary rounded t u rns bm 1449 g a u ss m a x operat i ng f l ux dens i t y at m i n i m u m s w i t c h i ng f r equenc y bp 2794 g a u ss m a x t r ans i ent f l ux dens i t y a t m i ni m u m s w i t c h i ng f r equenc y lp m i n 0. 342 m h enri e s m i ni m u m pri m ary m agnet i z i ng i nduc t a n c e (ass u m e s l g m a x - 5u m ) i m a g 0. 151 a m p s p eak m agnet i z i ng c u rrent a t m i ni m u m i nput vol t age od_p 0. 38 m m p r i m ary w i re out er di a m et er aw g _ p 27 aw g p r i m ary w i re gauge (rounded t o ma x i mu m a w g v a l u e ) d u t y cy c l e v a lu es duv o n m i n 0. 68 dut y c ycl e at m i n i m u m undervol t a ge t h res hol d dv m i n 0. 61 dut y c ycl e at m i n i m u m dc i npu t vol t age dv m a x 0. 29 dut y c ycl e at m a x i m u m dc i nput vol t age dov o ff m a x 0. 22 dut y c ycl e at m a x i m u m dc overvo l t age t h res hol d curre nt w a v e s h a p e p a r a m e t e rs ip 1. 835 am p s m a x i m u m peak pri m ary c u rrent at m a x i m u m dc i nput vol t age i p rm s 1. 246 a m p s m a x i m u m pri m ary rm s c u rrent at m i ni m u m dc i npu t vol t age coup l e d i nduct or out p ut p a r a m e t e rs lm a i n 8 8 . 0 u henri e s m a i n / out p u t 2 c oupl ed out pu t i nduc t a n c e (ref e rred t o m a i n w i ndi ng) w l m a i n 144 uj oul es m a i n / out p u t 2 c oupl ed i ndu c t or f u l l - l oad st ored energy pag e 15 o f 32 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w. p o we r i n t . c om
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 k d i m a i n 0. 20 current ri ppl e f a ct or of c o m b i ned m a i n and out put 2 ou t put s n o u t 2 0. 0 a pprox i m at e t u rns ra t i o f o r out p u t 2 w i ndi ng nb i a s 2. 3 a pprox i m at e t u rns ra t i o f o r b i as w i ndi ng s e cond a r y out p u t p a r a m e t e rs no derat i ng i s m a i n rm s l l 4. 67 a m p s m a x i m u m t r ansf o r m er s e c ondary rm s c u rrent (a c st ack ed s e c ondary) i s out2rm s l l 0. 00 a m p s m a x i m u m t r ansf o r m er s e c ondary rm s c u rrent (a c st ack ed s e c ondary) id avm a in 4 . 2 3 a m p s m a x i m u m average c u rrent , m a i n rec t i f i e r (si ngl e devi c e rat i ng) i d a v o u t 2 0. 00 a m p s m a x i m u m average c u rrent , m a i n rec t i f i e r (si ngl e devi c e rat i ng) i r ms ma i n 0 . 3 5 am p s m a x i m u m rm s c u rrent , m a i n ou t p ut c apac i t or i r m s o u t 2 0. 00 a m p s m a x i m u m rm s c u rrent , ou t 2 ou t put c apac i t or v p i v m a i n 39. 6 v ol t s m a i n rec t i f i e rs peak -i nvers e vol t age v p i v out2 0. 0 v ol t s out put 2 re c t i f i e rs peak -i nvers e vol t age v p i v b 58. 1 v ol t s b i as out put rect i f i e r peak -i nvers e vol t age p a ge 1 6 of 3 2 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 10 performance dat a al l me asur e m en ts p e r f or me d at r o o m t e m per atur e unl ess oth e r w i s e speci f i e d. 10.1 ef f i cienc y e p - 21 e f f i ci e n cy vs . ou t p u t p o w e r 0.6 0.65 0.7 0.75 0.8 0.85 0.9 01 0 2 0 3 0 4 0 o u tput po w e r (w) efficienc y (%) v in = 36 v v in = 48 v v in = 60 v v in = 72 v figur e 8 ? ?
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 10.2 regulation 10.2 . 1 loa d r e g u l a ti o n ep - 21 lo ad regu la tio n 95 . 0 96 . 0 97 . 0 98 . 0 99 . 0 1 00. 0 1 01. 0 1 02. 0 1 03. 0 1 04. 0 1 05. 0 01 2 3 4 5 6 out p ut cu r r e n t ( a ) r e g u la tio n ( % o f no m i n a l) v in = 36 v v in = 48 v v in = 60 v v in = 72 v figur e 1 0 ? loa d re gul ati on, r oom t e m per atur e. 10.2 . 2 li ne r e g u l a ti on e p - 2 1 line r e gula t ion 95. 0 96. 0 97. 0 98. 0 99. 0 100. 0 101. 0 102. 0 103. 0 104. 0 105. 0 35 40 45 50 55 60 65 70 75 dc i n p u t v o lt a g e out put r e gu lat i o n ( % of n o m i na l) i ou t = 6 a i ou t = 3 a i ou t = 0 a figur e 1 1 ? lin e re gu lat i o n , ro om t e m per atur e. p a ge 1 8 of 3 2 po w e r int e grat i ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w . p ow er i n t . co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 11 thermal pe rforma nce t h e r m a l pe r f o r m a n c e of th e e p - 2 1 w a s m easu r e d in still a i r a t ro om tem p e r a t u r e w i th n o heat si nk an d w i th a w a k e f i el d 6 28- 6 5 ab h eat si nk attac h e d to th e al u m i n u m su bstr at e using berq uist bo nd ply 105 th erm a l ad hesiv e. t h e su pply w a s also test ed in still air in a ther m a l cha m ber w i t h the a m bi e n t te mp er atur e a d j u ste d for 110 dpa-switc h (u1) 68 dpa-switc h (u1) 115 dpa-switc h (u1) 87
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 input volt age 36 vd c 48 vd c 72 vd c item am b i e n t 57 dpa-switc h (u1) 114
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 12 w a v e forms 12.1 d r ain volt age and c u rrent , n o rmal op erat i on figur e 1 7 ? ?
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 12.2 out put volt age st art - up prof ile figur e 2 0 ? figur e 2 1 ? figur e 2 2 ? figur e 2 3 ? figur e 2 4 ? star t- u p pr of i l e , 72 vdc, f u l l l oad. 1 v/ di v, 5 m s /div. figur e 2 5 ? p a ge 2 2 of 3 2 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 12.3 load transi ent r esp onse ( 7 5 % t o 10 0 % l o ad st ep) in the f i g u r e s s how n bel ow , si g nal a v er ag i ng w a s used to be tter en abl e v i ew i n g the l o a d tra n s ie n t re spo n s e. t h e o scillo sc o p e w a s trigge re d u s in g th e lo a d cu rre n t step a s a tr i g g e r sour ce. si nce the out put r i ppl e occ u r s essenti a l l y at r andom w i th r e spect to th e load transie nt, contrib u t ions t o the display e d t r ace form the o u tp ut ri pple w ill av erag e out, l eav i n g the contr i b u ti o n onl y f r om th e l o a d st ep r e sp ons e. figur e 2 6 ? upper t r ac e: lo ad c u r r ent, 2 a/ di v. bott om t r ac e: o u tput v o lt a ge, 50 m v /di v , 1 00 figur e 2 7 ? figur e 2 8 ? upper t r ac e: o u tp ut cur r e nt, 2 a/d i v. bott om t r ac e: o u tput v o lt a ge, 50 m v /di v , 1 00 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 12.4 out put r i pple m easu rement s 12.4 . 1 r i ppl e m eas ur em ent techni q ue for dc outpu t ripple m eas ure m en ts, a m o d i f i e d oscilloscop e tes t probe m u s t be utiliz ed i n or der to r e d u ce s p u r i ous si g nal s due to pi ckup. d e t a i l s o f th e p r obe m odi f i ca ti on ar e pr ov i ded i n fi g u r e 29 a nd fi g u r e 30 . t h e 5 125 ba pr ob e a d apter i s a f f i x ed w i th tw o cap a ci tor s ti ed i n par al l e l acr o ss t he pr ob e ti p. t he ca paci t or s i n cl ude on e ( 1 ) 0.1 the al um i num el ectrol yti c type ca paci tor i s pol ar iz ed, so pr oper pol ar i t y acr o ss d c out puts m u st be m a i n tai n ed ( s ee bel ow) . pr obe gr oun d pr obe t i p figur e 2 9 ? figur e 3 0 ? po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 12.4 . 2 m easur e m en t r e sul t s pag e 25 o f 32 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m figur e 3 1 ? ? ? ? ? ?
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 13 contr o l loop m e a s ur ement s 13.1 m aximum load 36 v d c ga i n phas e figur e 3 7 ? 13.2 m aximum load 48 v d c ga i n phas e figur e 3 8 ? po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter 13.3 m aximum load 72 v d c ga i n phas e figur e 3 9 ? po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 14 rev i sion histor y d a t e a u thor r e v i sion d escript i on & ch ang es 05- jun- 0 2 a p p 1 . 0 fi r s t r e l e a s e 10- jul - 02 app 2.0 pix l s spr eads hee t a d d ed 26- se p- 0 2 a p p 3 . 0 sche mati c upd ate d 19- n o v - 02 app 4.0 sche mati c, bom , and star t- up w a v e f o r m s up dat ed p a ge 2 8 of 3 2 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter n o t es pag e 29 o f 32 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 n o t es p a ge 3 0 of 3 2 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
19- n o v - 02 epr - 2 1 ? 5 v, 3 0 w d c - d c c onv er ter n o t es pag e 31 o f 32 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m
epr - 21 ? 5 v, 3 0 w d c - d c c onv er ter 19- n o v - 02 for the lat est u pdate s, v i sit our web s i te: www. p o w e r i n t. c o m pow e r integrat ion s re serv es t h e righ t to ma ke chan ges to its produ cts at a n y tim e to im prov e reli abi lity or manu fact urab ili ty . pow e r inte gratio ns doe s no t a ssu me any liab ility ar is ing fr om the use of any dev ice or circ uit des cribe d h e rein , nor doe s i t c onv ey any lic ens e un der its pa tent ri ght s or t he r i ght s of oth e r s . t he pi logo , topswitch , tinyswitch and ecosmart are reg i st ered trade mar ks of p o w e r integrat ion s , in c. ? c opy right 20 02, p o w e r integ r ation s , i n c. t he produ cts and app lic ati ons illu strat ed h e rei n (in c l udin g c i r c uit s ex ternal t o th e pro duc ts a nd tran sfor mer con s tru c tio n ) m a y be c o v e red by one or mor e u . s. a nd for e i gn pat ent s or pote n tia lly by pe nding u . s. an d for e ig n patent app li cati ons as si gned t o pow e r integra t io ns. a co mp l e te l i st of pow e r inte grat ion s ? patent s may be f oun d at www.p o w e r i n t. c o m . w o rl d he a d qu a r t e rs nort h a m e r i c a - w e s t p o w e r i n t egrat i ons, i n c. 5245 hel l y er a v enue s an j o s e , ca 95138 u s a . m a i n : +1-408-414-9200 c u s t om e r s e r v i c e: p hone: +1-408-414-9665 fax : +1-408-414-9765 e - m a il: us as al e s @ pow eri n t . c o m e urop e & a f ri c a p o w e r i n t egrat i ons (e urope) lt d. cent enni al court e a st ha m p st ead road b r ack nel l b e rks h i r e rg12 1 y q, uni t ed k i ngdo m p hone: +44-1344-462-300 fax : +44-1344-311-732 e - m a il: euros al es @ pow eri n t . c o m si n g a p o r e p o w e r i n t egrat i ons, s i ngapore 51 g o ldhill plaz a #16-05 republ i c of s i ngapore, 308900 p hone: +65-6358-2160 fax : +65-6358-2015 e - m a il: s i ngapores al e s @ pow eri n t . c o m ta i w a n p o w e r i n t egrat i ons i n t e rnat i onal hol d i ngs, i n c. 17f-3, no. 510 chung hs i ao e . rd. , se c . 5 , tai pei , tai w an 110, r. o . c. p hone: +886-2-2727-1221 fax : +886-2-2727-1223 e - m a il: t a i w an s a l e s @ pow eri n t . c o m chi n a p o w e r i n t egrat i ons i n t e rnat i onal hol d i ngs, i n c. rm # 1705, b ao hua b l dg. 1016 hua qi ang b e i lu s henzhen guangdong, 518031 p hone: +86-755-8367-514 3 fax : +86-755-8377-961 0 e - m a il: c h i nas al e s @ pow eri n t . c o m kore a p o w e r i n t egrat i ons i n t e rnat i onal hol d i ngs, i n c. rm # 402, handu k b u i l d i ng, 649-4 y eoks a m - dong, k angna m - gu, s eoul , k o rea p hone: +82-2-568-7520 fax : +82-2-568-7474 e-m a i l : k o reas al e s @ pow eri n t . c o m ja p a n p o w e r i n t egrat i ons, k . k . k e i h i n -tat e m ono 1st b l dg. 12-20 s h i n -y ok oha ma 2-chom e, k ohok u-k u , y o k oha m a - s hi , k anagaw a 222-0033, j apan p hone: +81-45-471-1021 fax : +81-45-471-3717 e - m a il: j apans al es @ pow eri n t . c o m i n d i a ( t echni cal s upport) i nnovat ec h #1, 8t h m a i n road v a s ant hnagar b angal ore, i ndi a 560052 p hone: +91-80-226-6023 fax : +91-80-228-9727 e - m a il: i ndi as al es @ p o w eri n t . c o m a p p l ic a t io n s h o t l in e w o rl d w i de +1-408-414- 9660 a p p l ic a t io n s f a x w o rl d w i de +1-408-414-9760 p a ge 3 2 of 3 2 po w e r i n tegrati ons, i n c. tel : +1 408 414 9660 fax : +1 408 414 9760 w w w .p ow er in t.co m

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