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RD2 TOPSwitch (R)
Reference Design Board
85 to 132 VAC or 170 to 265 VAC Input, 8W(10W Peak) Output
Product Highlights
Low Cost Production Worthy Reference Design * Only 21 components! * Single sided board * Low cost thru-hole components * Fully assembled and tested * Easy to evaluate and modify * Extensive performance data * Up to 77% efficiency * Light weight - no heat sink required for TOPSwitch Fully Protected by TOPSwitch * Primary safety current limit * Output short circuit protection * Thermal shutdown protects entire power supply Designed for World Wide Operation * Designed for IEC/UL safety requirements * Meets VDE Class B EMI specifications Typical Applications * Replacement for low power linear adapters * Auxiliary power supply for appliance, motor control, utility meters, smart building, UPS, etc.
1.4 in.
(R)
2.6 in.
0.8 in.
PI-1768-020596
Figure 1. RD2 Board Overall Physical Dimensions.
PARAMETER Input Voltage Range Input Frequency Range Temperature Range Output Voltage (Io = 0.67A) Output Power (continuous) Output Power (peak)
(85-132 VAC)
LIMITS 85 to 132 VAC 85 to 132 VAC or 170 to 265 VAC 47 to 440 Hz 0 to 70C 12 V 10% 8W 10 W 0.7% 5% 75% 50 mV MAX IEC 950 / UL1950 VDE B (VFG243 B) CISPR22
Description
The RD2 reference design board is an example of a very low cost production worthy power supply design using the TOPSwitch family of Three-terminal Off-line Switchers from Power Integrations. It is intended to help TOPSwitch users to quickly develop their products by providing a basic design that can be easily modified to fit a particular application. In most cases, a minor change to the transformer for a different output voltage or voltages is all that is needed. A complete set of performance curves, the parts list, the board layout and details on transformer design are provided to speed up the TOPSwitch based switcher design.
Line Regulation (170-265 VAC) Load Regulation (10%-100%) Efficiency (115 V input, 8 W out) Output Ripple Voltage Safety EMI
Figure 2. Table of Key Electrical Parameters.
May 1996
RD2
1 + BR1 DF06M RA 470 K JP1* JUMPER + C1 10 F 200 V T1 T1RD2
VR1 BZY97-C200
D1 UF4005 2
D2 MBR360 8 C2 330 F 16 V 5 +
L1 3.3 H C3 120 F 16 V +
12 V
R2 390 1W
C6 47nF 250VAC X2
RB 470 K
C9 10 F 200 V
+ U1
D C TOP 210 S S
D3 R1 1N4148 6.8 4
RTN
L2 8 mH 0.2A
+ C5 47 F 10 V 3
F1 2A
L N J1
C7 1nF 250 VAC Y1 * JPI CLOSED FOR 115 VAC INPUT JPI OPEN FOR 230 VAC INPUT
PI-1783-020596
Figure 3. Schematic Diagram of the RD2 Power Supply.
CAUTION
The RD2 features a 115/230 VAC selectable input, and is shipped configured for 230 VAC operation (JP1 open). If JP1 is used for 115 VAC operation, it must be removed before applying 230 VAC.
C6
BR1
+
VR1 D1 RA RB U1 R1 D3 T1 R2 + D2 C2 +
JP1 + L2 F1
L1
N
C1
+
+ C5
C7 C3 +
TOPSwitch RD2 L C9
8
-
PI-1817-040296
Figure 4. Component Legend of the RD2.
2
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RD2 Component Listing
Reference U1 D1 D2 D3 BR1 VR1 L1 L2 C1, C9 C2 C3 C5 C6 C7 RA, RB R1 R2 T1 F1
Figure 5. Parts List for the RD2.
Value
Part Number TOP210PFI UF4005 MBR360 1N4148 DF06M BZY97-C200 Custom SU9V-02080 KMG200VB10RM10X16 LXF16VB331M8X15 LXF16VB121M6.3X11.5 KME10VB47RM5X12.5 F1772-347-2000 DE1110 E 102M ACT4K-KD 5043CX470K0J 5043CX6R800J MO-1 391J T1RD2 19372, 2A
Manufacturer Power Integrations General Instruments Motorola Rohm General Instruments SGS/Thomson, Fagor Tokin United Chemicon United Chemicon United Chemicon United Chemicon Roederstein Murata Philips Philips Koa/Speer Wickman
600V, 1A, UFR Schottky, 3A, 60V 75 V Switching 1 A, 600 V 200 V Zener, 1.5 W 3.3 H, 4A 8 mH, 0.2A 10 F, 200V 330 F, 16V 120 F, 16V 47 F, 10V 47 nF, 250 VAC, X 2 1 nF, 250 VAC, Y1 470 K, 1/4 W 6.8 , 1/4 W 390 ohms, 1 W Custom 2A, 250 VAC
General Circuit Description
The RD2 is a low-cost, isolated Buck-Boost or flyback switching power supply using the TOP210 integrated circuit. The circuit shown in Figure 3 produces a 12 V, 8 W power supply that operates from 85 to 132 VAC or 170 to 264 VAC input voltage. The 12 V output voltage is determined by the TOPSwitch control pin shunt regulator voltage, the voltage drop of D3, and the turns ratio between the bias and output windings of T1. Other output voltages are also possible by adjusting the transformer turns ratios. R1 and C5 provide filtering of the bias winding to improve line and load regulation. AC power is rectified and filtered by BR1, C1 and C9 to create the high voltage DC bus applied to the primary winding of T1. The other side of the transformer primary is driven by the integrated high-voltage MOSFET inside the TOP210. JP1 is a jumper used to select 115 V or 230 V operation. Adding JP1 selects 115 V operation. Leaving JP1 open selects 230 V operation. RD2 is supplied with JP1 open. RA and RB equalize leakage currents between C1 and C9. D1 and VR1 clamp the leading-edge voltage spike caused by transformer leakage inductance to a safe value and reduce ringing. The power secondary winding is rectified and filtered by D2, C2, L1, and C3 to create the 12 V output voltage. R2 provides a pre-load on the 12 V output to improve load regulation at light loads. The bias winding is rectified and filtered by D3, R1, and C5 to create a bias voltage to the TOP210. Common-mode EMI currents which flow between the primary windings of the transformer and the secondary output circuitry are attenuated by L2 and C7. Differential-mode EMI currents caused by pulsating currents at the input of the power supply are attenuated by C6 and L2. C5 filters the internal MOSFET gate drive charge current spikes on the Control pin, determines the auto-restart frequency, and together with R1, compensates the control loop. The circuit performance data shown in Figures 6-18 was measured with AC voltage applied to the RD2. Load Regulation (Figure 6) - The amount of change in the DC output voltage for a given change in output current is referred to as load regulation. The 12 V output stays within 5% from 10% to 100% of rated load current. The TOPSwitch on-chip overtemperature protection circuit will safely shut down the power supply under sustained overload conditions.
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RD2 General Circuit Description (cont.)
Line Regulation (Figure 7) - The amount of change in the DC output voltage for a given change in the AC input voltage is called line regulation. The maximum change in output voltage is less than 0.7%. Efficiency (Line Dependent) - Efficiency is the ratio of the output power to the input power. The curves in Figures 8 and 9 show how the efficiency changes with input voltage. Curves are also given to show the difference in efficiency when C1 and C9 are changed from 10 F to 22 F. Efficiency (Load Dependent) - The curves in Figures 10 and 11 show how the efficiency changes with output power at 115 and 230 VAC inputs. The curves also show the increase in efficiency when C1 and C9 are changed from 10 F to 22 F. Power Supply Turn On Sequence - The internal switched, highvoltage current source provides the initial bias current for TOPSwitch when power is first applied. The waveforms shown in Figure 12 illustrate the relationship between the high-voltage DC bus and 12 V output voltage. Capacitors C1 and C9 charge to the peak of the AC input voltage before TOPSwitch turns on. The delay of 150 ms (typical) is caused by the time required to charge the auto-restart capacitor C5 to 5.7 V. At this point the power supply turns on as shown. Figure 13 shows the output voltage turn on transient. Line frequency ripple voltage is shown in Figure 14 for 115 VAC input and 8W output. Switching frequency ripple voltage is shown in Figure 15 for the same test condition. The power supply transient response to a step load change from 0.5 A to 0.67 A (75% to 100%) is shown in Figure 16. Note that the response is quick and well damped. The RD2 is designed to meet worldwide safety and EMI (VDE B) specifications. Measured conducted emissions are shown in Figure 17 for 115 VAC and Figure 18 for 230 VAC.
PI-1769-020596
Output Voltage (% of Nominal)
Output Voltage (% of Nominal)
VIN = 115 VAC 100
100.5 100 99.5 99 90 100 110
IOUT = 0.67 A IOUT = 0.17 A
95
0
100 200 300 400 500 600 700
120
130
Load Current (mA)
105 VIN = 230 VAC 100
Input Voltage (VAC)
101 100.5 100 99.5 99 180 200 220 240 260 IOUT = 0.67 A IOUT = 0.17 A
95
0
100 200 300 400 500 600 700
Load Current (mA)
Figure 6. Load Regulation
Input Voltage (VAC)
Figure 7. Line Regulation
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PI-1770-020596
105
101
RD2
PI-1771-020596
Output Efficiency (%)
Output Efficiency (%)
75 IOUT = 0.67 A IOUT = 0.67 A, C1, C9 = 22 F
75
IOUT = 0.67 A IOUT = 0.67 A, C1, C9 = 22 F
70
70
65 IOUT = 0.17 A 60 85 IOUT = 0.17 A, C1, C9 = 22 F 95 105 115 125 135
65 IOUT = 0.17 A IOUT = 0.17 A, C1, C9 = 22 F 60 170 190 210 230 250 270
Input Voltage (VAC) Figure 8. Efficiency vs. Input Voltage, 85-132 VAC
PI-1773-020596
Input Voltage (VAC)
Figure 9. Efficiency vs. Input Voltage, 170-265 VAC
PI-1774-020596
80
80
Output Efficiency (%)
Output Efficiency (%)
75
75
70
70
65
VIN = 115 VAC VIN = 115 VAC, C1, C9 = 22 F
65
VIN = 230 VAC VIN = 230 VAC, C1, C9 = 22 F
60 1 2 3 4 5 6 7 8
60 1 2
3
4
5
6
7
8
Output Power, (W) Figure 10. Efficiency vs. Output Power, 115 VAC Input
PI-1775-020596
Output Power (W) Figure 11. Efficiency vs. Output Power, 230 VAC Input
PI-1776-020596
DC BUS VOLTAGE
300 200 100 0 15 10 5 0 0 250
Output Voltage (V)
12 10 8 6 4 2 0
OUTPUT VOLTAGE
500
0
25
PI-1772-020596
80
80
50
Time (ms) Figure 12. Turn On Delay
Time (ms) Figure 13. Output Voltage Turn On Transient
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5
RD2
PI-1778-020596
PI-1777-020596
Output Voltage (mV)
Output Voltage (mV)
40 20 0 -20 -40
40 20 0 -20 -40
0
10
20
0
25
50
Time (m sec)
Time ( sec)
Figure 14. Line Frequency Ripple, 115VAC In, 8W Output
Figure 15. Switching Frequency Ripple, 115 VAC In, 8W Output
Output Current (A) Output Voltage (mV)
50 0 -50 0.8 0.6 0.4 0.2 0 0 10
20
Time (ms) Figure 16. Transient Load Response (75% to 100% of load)
PI-1818-040296 PI-1819-040296
PI-1779-020696
100
VDE B Limit (VFG243)
100
VDE B Limit (VFG243)
Amplitude (dBV)
80 60 40 20 0 0.01 0.1 1 10
Amplitude (dBV)
80 60 40 20 0 0.01 0.1 1 10
Frequency (MHz) Figure 17. EMI Characteristics at 115 VAC Input.
Frequency (MHz) Figure 18. EMI Characteristics at 230 VAC Input.
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RD2
8 5
1 130 T #38 AWG 2 3 6T 2X #28 AWG Triple Insulated 4
8 12 T #26 AWG Triple Insulated 5
PIN
1 2 3 4 5 8
FUNCTION
HIGH-VOLTAGE DC BUS TOPSwitch DRAIN PRIMARY-SIDE COMMON VBIAS RETURN OUTPUT
1 4
CORE# - PC40 EE16 (TDK) GAP FOR AL OF 250 nH/T2 BOBBIN# - BE-16-118CPH (TDK)
1
4
ELECTRICAL SPECIFICATIONS
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance 60 Hz, 1 minute, from pins 1-4 to pins 5, 8 Between pins 1-4 and pins 5, 8 All windings open All windings open Pins 5 and 8 shorted 3000 VAC 5.0 mm (min) 4.3 mH, 10% 700 kHz (min) 50 H (max)
NOTE: All inductance measurements should be made at 100 kHz
PI-1820-040296
Figure 19. Electrical specification of transformer T1RD2
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RD2
BIAS 3 4
TAPE
{
5 8 1 2 SECONDARY
}
TAPE
PRIMARY
WINDING INSTRUCTIONS
Two-layer "C" Wound Primary Start at pin 2. Wind 65 turns of 38 AWG heavy nyleze wire from left to right. Apply 1 layer of tape (white polyester film 8.3 mm (0.32 in.) wide by 0.056 mm (2.2 mil) thick) for basic insulation. Continue winding 65 turns from right to left. Finish at pin1. Apply 2 layers of tape for basic insulation. Start at pin 8. Wind12 turns of triple-insulated 26 AWG wire* from right to left. Finish at pin 5. Apply 2 layers of tape for basic insulation. Start at pin 4. Wind 6 turns of 28 AWG triple insulated wire* parallel bifilar in a single layer, from left to right. Finish at pin 3. Apply 3 layers of tape for basic insulation. Assemble and secure core halves. Impregnate uniformly with varnish.
Basic Insulation Triple Insulated Secondary
Basic Insulation Parallel Bifilar Primary Bias
Outer Insulation Final Assembly
* Triple insulated wire sources. P/N: order by description Rubudue Wire Company 5150 E. La Palma Avenue Suite 108 Anaheim Hills, CA 92807 (714) 693-5512 (714) 693-5515 FAX P/N: order by description Furukawa Electric America, Inc. 200 Westpark Drive Suite 190 Peachtree City, GA 30269 (770) 487-1234 (770) 487-9910 FAX P/N: order by description The Furukawa Electric Co., Ltd 6-1, Marunouchi 2-chome, Chiyoda-ku, Tokyo 100, Japan 81-3-3286-3226 81-3-3286-3747 FAX
PI-1740-010596
Figure 20. Construction details of transformer T1RD2
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RD2
Notes
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9
RD2
Notes
10
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RD2
Notes
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RD2
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, nor does it convey any license under its patent rights or the rights of others. PI Logo and TOPSwitch are registered trademarks of Power Integrations, Inc. (c)Copyright 1994, Power Integrations, Inc. 477 N. Mathilda Avenue, Sunnyvale, CA 94086
WORLD HEADQUARTERS Power Integrations, Inc. 477 N. Mathilda Avenue Sunnyvale, CA 94086 USA Main: 408*523*9200 Customer Service: Phone: 408*523*9265 Fax: 408*523*9365 JAPAN Power Integrations, Inc. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2-Chome.Kohoku-ku Yokohama-shi, Kanagawa 222 Japan Phone: 81*(0)*45*471*1021 Fax: 81*(0)*45*471*3717 AMERICAS For Your Nearest Sales/Rep Office Please Contact Customer Service Phone: 408*523*9265 Fax: 408*523*9365 EUROPE & AFRICA Power Integrations (Europe) Ltd. Mountbatten House Fairacres Windsor SL4 4LE United Kingdom Phone: 44*(0)*1753*622*208 Fax: 44*(0)*1753*622*209
ASIA & OCEANIA For Your Nearest Sales/Rep Office Please Contact Customer Service Phone: 408*523*9265 Fax: 408*523*9365
APPLICATIONS HOTLINE World Wide 408*523*9260 APPLICATIONS FAX Americas 408*523*9361 Europe/Africa 44*(0)*1753*622*209 Japan 81*(0)*45*471*3717 Asia/Oceania 408*523*9364
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