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Design Example Report
Title Specification Application Author Document Number Date Revision 15W Flyback Power Supply using TOP244P Input: 90 - 265 VAC 50/60Hz Output: +24 VDC @ 625mA Refrigerator Power Integrations Applications Department DER-106 May 19, 2006 1.1
Summary and Features * * * * * * * Low part count, Low-cost Isolated Flyback Power Supply E-SHIELD(R) Transformer Construction for reduced common-mode EMI (small 220pF Y1 capacitor and small 10mH Common-mode choke) 132kHz Switching Frequency with jitter to reduce conducted EMI Auto-restart function for automatic and self-resetting open-loop, overload and shortcircuit protection Built-in Hysteretic thermal shutdown at 135C Enhanced 8-pin DIP package with increased creepage from Drain to low-voltage control pins EcoSmart(R) for extremely low standby power consumption <800 mW at 230 VAC
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 Atlanta Sales Office 4335 South Lee Street - G, Buford, GA 305188 USA. Tel: +1 678 714 6011 Fax: +1 678 714 6012 www.powerint.com
DER-106
15 W Universal Input Power Supply
May 19, 2006
Table Of Contents
1 2 3 4 Introduction .................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic ...................................................................................................................5 Circuit Description.......................................................................................................6 4.1 Input EMI Filtering................................................................................................6 4.2 TOPSwitch Primary .............................................................................................6 4.3 Output Rectification .............................................................................................6 4.4 Output Feedback .................................................................................................7 5 PCB Layout.................................................................................................................8 6 Bill Of Materials...........................................................................................................9 7 Transformer Specification .........................................................................................10 8 Transformer Spreadsheets .......................................................................................14 9 Performance Data.....................................................................................................17 9.1 Efficiency ...........................................................................................................17 9.2 No-load Input Power ..........................................................................................17 9.3 Regulation .........................................................................................................18 9.3.1 Load ...........................................................................................................18 9.3.2 Line.............................................................................................................18 10 Waveforms ............................................................................................................19 10.1 Drain Voltage and Current, Normal Operation...................................................19 10.2 Output Voltage Start-up Profile ..........................................................................19 10.3 Drain Voltage and Current Start-up Profile ........................................................20 10.4 Load Transient Response (75% to 100% Load Step)........................................21 10.5 Output Ripple Measurements ............................................................................22 10.5.1 Ripple Measurement Technique.................................................................22 10.5.2 Measurement Results.................................................................................23 11 Control Loop Measurements .................................................................................24 11.1 90 VAC Maximum Load.....................................................................................24 11.2 265 VAC Maximum Load...................................................................................25 12 Conducted EMI .....................................................................................................26 13 Revision History ....................................................................................................27
Important Notes: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolated source to provide power to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
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DER-106
15 W Universal Input Power Supply
May 19, 2006
1 Introduction
This document is an engineering report describing the design of an AC-DC power supply with universal input providing a regulated +24 VDC at 625 mA. The design, rated for 15 W is implemented using a TOP244P device from the TOPSwitch-GX IC family and an EEL19 core in a Flyback topology. This power supply is intended to be used in a refrigerator appliance where the maximum ambient temperature can reach 70C. 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-106
15 W Universal Input Power Supply
May 19, 2006
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 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Safety Surge
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Symbol VIN fLINE
Min 90 47
Typ
Max 265 64 0.8
Units VAC Hz W V mV A W W %
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 POUT POUT_PEAK
24 100 0.625 15 20 82
5% 20 MHz bandwidth
Measured at POUT (15 W), 25 C
o
4
kV
Surge Ambient Temperature TAMB
3 0 70
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-106
15 W Universal Input Power Supply
May 19, 2006
3 Schematic
Figure 2 - Schematic
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DER-106
15 W Universal Input Power Supply
May 19, 2006
4 Circuit Description
The schematic in Figure 2 shows an off-line Flyback converter using the TOP244P. The circuit is designed for 90 VAC to 265 VAC input and provides a single output; +24 V @ 625 mA. 4.1 Input EMI Filtering Conducted EMI filtering is provided by C8, C11, C18 and T4. The switching frequency jitter feature of the TOPSwitch-GX family allows the use of a small, low cost common mode choke for T4 and reduces the value of C8 and C11 needed to meet EN55022 / CISPR22 Class B with good margin. A safety rated Y capacitor bridges the isolation barrier from the rectified DC rail to output return. This returns common mode EMI currents generated by the primary and secondary switching-waveforms, reducing conducted EMI. EMI results are presented in a later section of this document. Returning the Y capacitor to the DC rail ensures high currents present during line transients are routed away from U1. 4.2 TOPSwitch Primary To keep the peak DRAIN voltage acceptably below the BVDSS (700 V) of U5, diode D10, R7, VR2, C20, and R6 form a primary clamp. This network clamps the voltage spike seen on the DRAIN due to primary and secondary reflected leakage inductance. Capacitor C20 together with R6 form the main clamp with VR2 providing a hard limit for the maximum voltage seen across the primary. Resistor R7 ensures that VR2 only conducts at the end of the leakage inductance spike event, limiting dissipation. Diode D10 is deliberately selected as a slow recovery type, but must be a glass-passivated type to guarantee the reverse recovery time as defined by the manufacturer. Standard 1N4007 diodes should not be used as their potential for very long reverse recovery times can cause excessive drain ringing. The slow recovery time, compared to fast or ultra-fast diodes, allows recovery of some of the clamp energy, improving efficiency. The discrete full bridge rectifier bridge comprised of D11-D14 and C18 provide a high voltage DC BUS for the primary circuitry. The DC rail is applied to the primary winding of T5. The other side of the transformer primary is driven by the integrated MOSFET in U5. R5 sets the U5 current limit to approximately 70% of its nominal value. This limits the output power delivered during fault conditions. C3 has 3 functions. It provides the energy required by U5 during startup, sets the auto-restart frequency during fault conditions, and also acts to roll off the gain of U5 as a function of frequency. R2 adds a zero to stabilize the power supply control loop. Diode D9 and C17 provide rectified and filtered bias power for U5 and U7. 4.3 Output Rectification The output of T5 is rectified and filtered by D8 and C7. Inductor L2 and C21 provide additional high frequency filtering. Resistor R1 and C1 provide snubbing for D8. Choosing the proper snubber values is important for low zero-load power consumption and for high frequency EMI suppression. The snubber components were chosen so that the turn-on
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DER-106
15 W Universal Input Power Supply
May 19, 2006
voltage spike at the D8 anode is slightly under-damped. Increasing C1 and reducing R1 will improve damping and high frequency EMI, at the cost of higher zero-load power consumption. 4.4 Output Feedback Resistors R15 and R16 divide down the supply output voltage and apply it to the reference pin of error amplifier U6. Shunt regulator U6 drives Optocoupler U7 through resistor R17 to provide feedback information to the U1 CONTROL pin. The Optocoupler output also provides power to U5 during normal operating conditions. Components R2, R17, R14, C3 and C16 all play a role in compensating the power supply control loop. Capacitor C3 rolls off the gain of U1 at relatively low frequency. Resistor R2 provides a zero to cancel the phase shift of C3. Resistor R17 sets the gain of the direct signal path from the supply output through U7 and U6. Components C16 and R14 roll off the gain of the error amplifier (U6).
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DER-106
15 W Universal Input Power Supply
May 19, 2006
5 PCB Layout
Figure 3 - Printed Circuit Layout
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DER-106
15 W Universal Input Power Supply
May 19, 2006
6 Bill of Materials
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
QTY Ref Des 1 C1 2 1 1 1 1 2 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 C3 C17 C7 C8 C11 C16 C18 C19 C20 C21 D8 D9 D10 D11 D12 D13 D14 F2 L2 R1 R2 R5 R6 R7 R14 R15 R16 R17 RV2 T4 T5 U5 U6 U7 VR2
Value Mfg Part Number 470pF/200V 47uF 330uF 47nF 220pF 100nF 22uF 10nF 100uF MUR420 1N4148 1N4007GP 2A 3.3uH 47R 6.8 10.5 k 68 1k 10 k 40.2 k 4.75 k 470 275Vac 10mH EEL19 TOP244P TL431 PC817D P6KE130A
Description 470pF, 200 V, Ceramic, NPO 47uF, 25 V, Electrolytic, Low ESR, 500mOhm, (5 x LXZ25VB47RME11LL 11.5) 330uF, 35 V, Electrolytic, Very Low ESR, 38mOhm, KZE35VB331MJ16LL (10 x 16) ECQ-U2A473ML 47nF, 275 VAC, Film, X2 220pF, Ceramic, Y1 ECU-S1H104KBB 100nF, 50 V, Ceramic, X7R EEU-EB2G220 22uF, 400 V, Electrolytic, High Ripple, (12.5 x 25) ECK-D3A103KBP 10nF, 1 kV, Disc Ceramic 100uF, 35 V, Electrolytic, Low ESR, 180mOhm, (6.3 x LXZ35VB101M515LL 15) MUR420 200 V, 4 A, Ultrafast Recovery, 25 ns 1N4148 75 V, 300mA, Fast Switching, DO-35 1N4007GP 3-721-200-041 822LY-3R3M CFR-25JB-47R CFR-25JB-6R8 MFR-25FBF-10K5 CFR-25JB-68R CFR-25JB-1K0 CFR-25JB-10K MFR-25FBF-40K2 MFR-25FBF-4K75 CFR-25JB-470R V275LA4 SC-01-E100G YW-379-02B TOP244P TL431CLP ISP817D, PC817X4 P6KE170A 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 2 A, 250V, Slow, TR5 3.3uH, 2.66 A 47R, 5%, 1/4 W, Carbon Film 6.8 R, 5%, 1/4 W, Carbon Film 10.5 k, 1%, 1/4 W, Metal Film 68 R, 5%, 1/4 W, Carbon Film 1 k, 5%, 1/4 W, Carbon Film 10 k, 5%, 1/4 W, Carbon Film 40.2 k, 1%, 1/4 W, Metal Film 4.75 k, 1%, 1/4 W, Metal Film 470 R, 5%, 1/4 W, Carbon Film 275 V, 23 J, 7 mm, RADIAL 10mH, 1A, Common Mode Choke Bobbin, EEL19, Vertical, In built margins, 10 pins TOPSwitch-GX, TOP244P, DIP-8B 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92 Opto coupler, 35 V, CTR 300-600%, 4-DIP 170 V, 5 W, 5%, TVS, DO204AC (DO-15)
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DER-106
15 W Universal Input Power Supply
May 19, 2006
7 Transformer Specification
Transformer Construction
Electrical Diagram
Winding Order
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DER-106
15 W Universal Input Power Supply
May 19, 2006
Core Information
Core Type Core Material Gap length, mm EEL19 NC-2H or Equivalent 0.109
Bobbin Information
Bobbin Reference Bobbin Orientation Number of Primary pins Generic, 5 pri. + 5 sec. Vertical 5
Gapped Effective Inductance, 203 nH/t^2 Primary Inductance, uH 884
Number of Secondary 5 pins Margin on Left, mm Margin on Right, mm 3.0 3.0
Primary Winding
Parameter Number of Turns Wire Size, AWG Filar Layers Start Pin(s) Termination Pin(s) Section 1 66 28 1 2 3 1
BIAS Winding
Parameter Number of Turns Wire Size, AWG Filar Layers Start Pin(s) Termination Pin(s) Value 8.0 25 1 0.30 5 4
Shield Information
Parameter Number of Turns Wire Size, AWG Filar Layers Start Pin(s) Termination Pin(s) Primary 14 26 2 1 NC 1 Cancellation 25 31 2 1 1 NC
Secondary Winding
Parameter Spec Voltage, V Spec Current, A Actual Voltage, V Number of Turns Wire Size, AWG Filar Output 1 (main) 24.00 0.65 24.00 15 26 T.I.W. 1
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DER-106
15 W Universal Input Power Supply
May 19, 2006
Filar Layers Start Pin(s) Termination Pin(s)
1 0.50 9,10 6,7
Winding Instruction
Use 3.0 mm margin on the left side. Use 3.0 mm margin on the right side. Cancellation Shield Winding Start on pin(s) 1 using item [6] at the start leads and wind 25 turns (x 2 filar) of item [8]. in exactly 1 layer. Leave this end of cancellation shield winding not connected. Bend the end 90 deg and cut the wire in the middle of the bobbin. Add 1 layer of tape, item [4], to secure the winding in place. Primary Winding Start on pin(s) 3 using item [6] at the start leads and wind 66 turns of item [8] in 2.00 layer(s) from left to right. Add 1 layer of tape, item [5], in between each primary winding layer. At the end of 1st layer, continue to wind the next layer from right to left. On the final layer, spread the winding evenly across entire bobbin. Finish winding on pin(s) 1 using item [6] at the finish leads. Add 1 layer of tape, item [4], for insulation. Bias Winding Start on pin(s) 5 using item [6] at the start leads and wind 8.0 turns (x 1 filar) of item [9]. Spread the winding evenly across entire bobbin. Finish on pin(s) 4 using item [6] at the finish leads. Add 1 layer of tape, item [4], for insulation. Primary Balanced Shield Winding Start on any (temp) pin on the secondary side and wind 14 turns (x 2 filar) of item [10]. Spread the winding evenly across entire bobbin. Finish this winding on pin(s) 1 using item [6] at the finish leads. Cut out wire connected to temp pin on secondary side. Leave this end of primary shield winding not connected. Bend the end 90 deg and cut the wire in the middle of the bobbin. Add 3 layers of tape, item [4], for insulation. Secondary Winding Start on pin(s) 9,10 using item [6] at the start leads and wind 15 turns (x 1 filar) of item [10]. Spread the winding evenly across entire bobbin. Finish on pin(s) 6, 7 using item [6] at the start leads. Add 2 layers of tape, item [4], for insulation. Core Assembly Assemble and secure core halves. Item [1]. Varnish Dip varnish uniformly in item [7]. Do not vacuum impregnate.
Materials
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DER-106
15 W Universal Input Power Supply
May 19, 2006
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10]
Description Core: EEL19, NC-2H or Equivalent, gapped for ALG of 203 nH/t^2 Bobbin: Generic, 5 pri. + 5 sec. Tape: Polyester web 3.0 mm wide Barrier Tape: Polyester film 19.70 mm wide Separation Tape: Polyester film 13.7 mm wide Teflon Tubing # 22 Varnish Magnet Wire: 31 AWG, Solderable Double Coated Magnet Wire: 25 AWG, Solderable Double Coated Magnet Wire: 26 AWG, Triple Insulated Wire
Electrical Test Specifications
Parameter Electrical Strength, VAC Primary Inductance, uH Condition 60 Hz 1 minute, from pins 1 - 2 to pins 6 - 10. Spec 3000
Measured between Pin 1 to Pin 2, with all other Windings 884 uH +/open. 10%
Primary Leakage, uH Measured between Pin 1 to Pin 2, with all other Windings 44 uH (max) shorted.
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DER-106
15 W Universal Input Power Supply
May 19, 2006
8 Transformer Spreadsheets
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DER-106
15 W Universal Input Power Supply
May 19, 2006
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DER-106
15 W Universal Input Power Supply
May 19, 2006
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15 W Universal Input Power Supply
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9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency
Figure 4 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
9.2
No-load Input Power
Figure 5 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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DER-106 9.3 Regulation
15 W Universal Input Power Supply
May 19, 2006
9.3.1 Load
Figure 6 - Load Regulation, Room Temperature
9.3.2 Line
Figure 7 - Line Regulation, Room Temperature, Full Load
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DER-106
15 W Universal Input Power Supply
May 19, 2006
10 Waveforms
10.1 Drain Voltage and Current, Normal Operation
Figure 8 - 90 VAC, Full Load. Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 100 V, 2 s / div
Figure 9 - 265 VAC, Full Load Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 200 V / div
10.2 Output Voltage Start-up Profile
Figure 10 - Start-up Profile, 120 VAC 2 V, 20 ms / div.
Figure 11 - Start-up Profile, 240 VAC 2 V, 20 ms / div.
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DER-106
15 W Universal Input Power Supply
May 19, 2006
10.3 Drain Voltage and Current Start-up Profile
Figure 12 - 90 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 100 V & 1 ms / div.
Figure 13 - 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 200 V & 1 ms / div.
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DER-106
15 W Universal Input Power Supply
May 19, 2006
10.4 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 14 - Transient Response, 120 VAC, 75-10075% Load Step. Top: Load Current, 0.5 A/div. Bottom: Output Voltage 100 mV, 5msec / div.
Figure 15 - Transient Response, 240 VAC, 75-10075% Load Step Upper: Load Current, 0.5 A/ div. Bottom: Output Voltage 100 mV, 5 ms / div.
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DER-106
15 W Universal Input Power Supply
May 19, 2006
10.5 Output Ripple Measurements 10.5.1 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 16 and Figure 17. 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 16 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 17 - 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-106
15 W Universal Input Power Supply
May 19, 2006
10.5.2 Measurement Results
Figure 18 - +24 V Ripple, 90 VAC, Full Load. 2 ms, 20 mV / div
Figure 19 - +24 V Ripple, 265 VAC, Full Load. 2 ms, 20 mV / div
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DER-106
15 W Universal Input Power Supply
May 19, 2006
11 Control Loop Measurements
11.1 90 VAC Maximum Load
Figure 20 - Gain-Phase Plot, 90 VAC, Maximum Steady State Load Vertical Scale: Gain = 8 dB/div, Phase = 40 /div. Crossover Frequency = 1.42 kHz Phase Margin = 52.7
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DER-106
15 W Universal Input Power Supply
May 19, 2006
11.2 265 VAC Maximum Load
Figure 21 - Gain-Phase Plot, 265 VAC, Maximum Steady State Load Vertical Scale: Gain = 8 dB/div, Phase = 40 /div. Crossover Frequency = 695Hz, Phase Margin = 65.4
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DER-106
15 W Universal Input Power Supply
May 19, 2006
12 Conducted EMI
A conducted EMI scan of the prototype was taken to determine the effectiveness of the input filter and transformer ESHIELD(R) construction. The following plots show the peak performance of the converter against quasi-peak (QP) and average (AVG) limits of EN55022 Class B. Both scans were taken at 120 VAC / 60Hz input with maximum load applied to the outputs. Since the peak scans are below the average limits, it is expected that the QP and Average scans would have greater than 5db of margin below the limits.
Figure 22 - Conducted EMI (Neutral), Maximum Load, 120 VAC, 60 Hz, and EN55022 B Limits
Figure 23 - Conducted EMI (Line), Maximum Load, 120 VAC, 60 Hz, and EN55022 B Limits
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DER-106
15 W Universal Input Power Supply
May 19, 2006
13 Revision History
Date 10-26-05 05-19-06 Author RSP RSP Revision 1.0 1.1 Description & changes Initial Release Corrected Schematic Reviewed KM/JC/VC
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DER-106
15 W Universal Input Power Supply
May 19, 2006
For the latest updates, visit our website: www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NONINFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) 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 grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, EcoSmart, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)Copyright 2005 Power Integrations, Inc.
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15 W Universal Input Power Supply
May 19, 2006
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