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power integrations 5245 hellyer avenue, san jose, ca 95138 usa. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com title engineering prototype report for ep-34 ? single output 30 w ac-dc power supply using top245y ( topswitch ? -gx ) specification universal input, 12 v at 30 w output application generic author power integrations applications department document number EPR-34 date 10-feb-04 revision 1.1 features ? universal input 85 vac to 265 vac ? low parts count ? zero load power consumption <0.3 w at 115 vac, <0.45 w at 230 vac ? meets cispr22b emi with margin ? efficiency >80% 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 comp lete list of power integrations? patents may be found at www.powerint.com .
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 table of contents 1 introducti on ................................................................................................................. 4 2 power supply s pecificat ion ........................................................................................ 5 3 schemat ic ................................................................................................................... 6 4 circuit desc ription ...................................................................................................... 7 4.1 input emi f iltering ............................................................................................... 7 4.2 topswitch primary ............................................................................................. 7 4.3 output rectif ication ............................................................................................. 7 4.4 output f eedback ................................................................................................. 7 5 pcb lay out ................................................................................................................ 9 6 bill of ma te rials ........................................................................................................ 10 7 transforme r spec ificatio n ......................................................................................... 11 7.1 electrical diagram ............................................................................................. 11 7.2 electrical spec ifications ..................................................................................... 11 7.3 material s ............................................................................................................ 11 7.4 transforme r build diagram ............................................................................... 12 7.5 transforme r cons tructi on .................................................................................. 12 7.6 transforme r s ources ......................................................................................... 12 8 transforme r sp readsheet s ....................................................................................... 13 9 performanc e data .................................................................................................... 15 9.1 efficienc y ........................................................................................................... 15 9.2 no-load input power .......................................................................................... 15 9.3 regulati on ......................................................................................................... 16 9.3.1 load ........................................................................................................... 16 9.3.2 line ............................................................................................................ 16 9.4 overload po wer ................................................................................................. 17 10 thermal perf ormance ........................................................................................... 18 11 wavefo rms ............................................................................................................ 19 11.1 drain voltage and cur r ent, normal oper ation ................................................... 19 11.2 output voltage star t-u p pr ofile .......................................................................... 19 11.3 drain voltage and cur r ent start-u p profile ........................................................ 19 11.4 load transient response ( 75% to 100% load step) ....................................... 20 11.5 output ripple m easurement s ............................................................................ 21 11.5.1 ripple measurement t e chnique ................................................................ 21 11.5.2 measurement result s ................................................................................ 22 12 control loop m easurement s ................................................................................. 23 12.1 115 vac m a xi mum load................................................................................... 23 12.2 230 vac m a xi mum load................................................................................... 23 13 conducted emi ..................................................................................................... 24 14 ac surge and 100 khz ri ng wave i mmunity ....................................................... 25 14.1 common mode surge, 1.2/50 s ....................................................................... 25 14.2 differential mode surge, 1.2/50 s .................................................................... 26 14.3 common mode, 100 kh z ring wa ve ................................................................ 26 14.4 differential mode, 100 khz ring wave .............................................................. 26 15 revision hi story .................................................................................................... 27 page 2 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input important note: although the ep-34 is designed to satisfy safe ty isolation requirements, the engine ering prototype has not been agency approved. ther efore, all testing should be per formed using an is olation transforme r to provide the ac input to the prototype board. page 3 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 1 introduct i on this document is an engineerin g report describing a 12 v, 30 w universal input flyback power supply, intended as a st andard evaluation platform for topswitch-gx . the document contains the power supply spec ific ation, schematic, bill of materials, transformer documentation, printed circ uit board layout , and performance data. figure 1 ? ep-34 popul ated circuit bo ard. page 4 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 2 power supply s p ecificatio n des c ription sy mbol min ty p max units c o mment input voltage v in 8 5 2 6 5 v a c 2 wire ? no p.e. freq uen cy f line 4 7 5 0 / 6 0 6 4 h z no-l oad inp u t power (230 vac) 0.45 w outpu t output voltag e v out 1 1 . 4 1 2 . 0 0 1 2 . 6 v 5% output rip p le voltage v ripple 1 5 0 m v 20 mhz band w i d t h output current i out 0 2 . 5 a total ou tpu t po w e r contin uou s o u tput powe r p out 3 0 w efficiency 8 0 % measured at p ou t (30 w), 25 o c en v i ronmental c o nd uc te d e m i meets cispr22 b / en55022b s a f e t y designed to mee t iec950, ul1950 class ii s u r g e 4 k v 1.2/50 s surge, iec 1000-4 - 5, 2 / 12 ? series impedance, differential common mode s u r g e 3 k v 100 khz ring w a v e , 500 a short circuit current, differential and common mode ambient tem peratu r e t am b 0 5 0 o c free convection, sea level page 5 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 3 schematic figure 2 ? ep-34 sc hematic . page 6 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 4 circuit descriptio n the schem atic in figure 2 shows an off-line flyback converter using the top245y. th e circuit is designed for 85 vac to 265 vac i nput and provides an isolated 12 v, 2.5 a output. 4.1 input em i filtering capac itor cx1 and the leakage inductanc e of l1 filter differenti a l mode conducted emi. inductor l1 and cy1 filter common mode conducted emi. 4.2 topswitch primary rectifier bridge br1 and c1 pr ovide a high voltage dc supply rail for the primary circuitry. the dc rail is applied to the pr i m ary winding of t1. the other side of the transformer primary is driven by t he integrat ed mosfet in u1. diode d1 and vr1 clamp leakage spikes gener ated when t he mosfet in u1 s witches off. capacitor c2 reduces the operating temperature of vr1 by bypassi ng the leading edge of the primary leakage spike away from vr1. resistor r3 provides damping to reduce drain ringing improving emi. resis t or r1 sets the low-line turn-on threshold to approximately 69 vac and sets the overvoltage shutdown level to approximat ely 320 vac. resistor r4 sets the u1 current limit to approximately 70% of its nominal value. re sist or r2 reduces the u1 current limit as a func tion of line voltage so that maximum overload po wer is relatively constant (<50 w) over the entire input voltage range. this limits the output power deliv ered during fault conditions. capac itor c4 bypass es the u1 co ntrol pin while c3 has three functions. it provides the energy r equired by u1 during startup, sets the auto- restart frequency during fault condi tions, and als o ac ts to roll off the gain of u1 as a function of frequency. resistor r5 adds a zero to the control loop to stabilize the power supply. diode d2 and capacitor c5 provide rectified and f iltered bias power for u2 an d u1. 4.3 output rectification the secondary of t1 is re ctified and filtered by d3, c6, and c7. inductor l2 and c8 provide additional high frequenc y filtering. resistor r11 and c11 provide snubbing f o r d3. choosing the proper s nubber values is im portant for low zero-load po wer consumption and for high frequency emi s uppression. the snubber components wer e chosen so that the turn-on voltage spike at the d3 anode is s lightly under-damped. increasing c11 and r educing r 11 will improve damping and high frequency emi, at the cost of higher zero load power consumption. 4.4 output feedback resistors r9 and r10 di vide down the supply output voltage and apply it to the reference pin of error amplifier u3. shunt regulator u3 drives t he led of optocoupler u2 through resistor r6 to provide feedback information to the u1 control pin. the optocoupler output als o provides power to u1 from the bias winding during normal operating conditions. diode d4 and capacitor c10 apply dr ive to the optocoupler during supply page 7 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 startup to reduce output voltage overshoot (soft finish network). diode d4 also is olat es c10 from the supply f eedback loop after start up. resistor r7 discharges c10 when the supply is off. components c3, c9, r5, r6, and r8 all play a role in compens ating the power supply control loop. capacit or c3 rolls off the gain of u1 at relatively lo w frequenc y. resistor r5 provides a zero to cancel the phase shift of c5. res i stor r6 set s the gain of the direc t signal path from the supply output through u2 and u3. components c9 and r8 roll of f the gain of u3. page 8 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 5 pcb la yout figure 3 ? ep-34 printe d circuit board layout (dim e n sio n s 0.0 01?). page 9 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 6 bill of materials ep-34 ? 12 v, 30 w topswitch- g x evaluation board bill of mat e rials item qt y ref e ren c e des c ription p/n manuf ac ture r 1 1 u1 topswitch-gx ic t o p245y po w e r integr ati ons 2 1 u2 optocoup ler, isp817c isocom control l ed ct r 3 1 u3 adj. shunt re g u lator lm43 1cz natio nal sem i c ond uctor 4 1 vr1 t v s, 600 w , 2 00 v p6ke20 0 on semicon d u c tor 5 1 br1 bridg e , 600 v, 2 a 2kbp06m genera l semic ond uctor 6 1 d1 600 v, 1 a, uf r uf 400 5 genera l semic ond uctor 7 2 d2, 4 diod e , 75 v 1n4 148 an y 8 1 d3 100 v, 10 a, schottk y mbr10 100 genera l semic ond uctor 9 1 cx1 x2 c apac itor, 2 20 nf ecq-u2a2 24 ml panas onic 10 1 c1 68 f , 400 v, 105 c kmx4 00vb 6 8 r m18 x 25l l unite d chem ic on 18 mm x 25 mm 11 1 c2 ceramic d i sk, 4.7 nf , 1 kv 5gad47 visha y 12 1 c3 47 f , 16 v, 1 05 c kme16vb4 7r m5x11 l l unite d chem ic on 13 2 c4, 9 100 nf , 50 v, ceramic c32 0 c1 04k 1r 5ca kemet 14 1 c5 1 f , 50 v, 105 c kme50vb1 r0 m5x11 l l unite d chem ic on 15 1 cy1 2.2 nf y1 440 ld2 2 cera-mite 16 2 c6, 7 560 f , 35 v lxz 35vb5 61m 10 x2 5l l unite d chem ic on 1 0 m m x 2 5 m m (esr 45 m ? ) 17 1 c8 100 f , 35 v kme35vb1 01 m8x11 l l unite d chem ic on 18 1 c10 10 f , 50 v, 1 05 c kme50vb1 0r m5x11 l l unite d chem ic on 19 1 c11 470 pf , 10 0 v c31 5 c4 71k 1r 5ca kemet 20 1 t 1 t r ansformer, ef 25 sil602 0, rev. 6 hical nl 02 1 21 8 11 vogt 21 1 l1 balu n, 20 mh, 0.8 a elf - 18n 008a panas onic 22 1 l2 3.3 h, 2.7 a 622 ly3r 3m t o ko, or equiv. 23 1 f 1 f u se, 3.15 a, 250 vac 372- 131 5 w i ckman t i m e d e l a y 24 1 r1 2 m ? , 1/2 w , 5 % an y 25 1 r2 8.2 m ? , 1/2 w , 5% an y 26 1 r3 68 ? , 1/2 w , 5% an y 27 1 r4 12.1 k ? , 1%, 1/8 w size any 28 1 r5 6.8 ? , 1/8 w , 5 % an y 29 1 r6 1 k ? , 1/8 w , 5 % an y 30 1 r7 15 k ? , 1/8 w , 5% an y 31 1 r8 3.3 k ? , 1/8 w , 5% an y 32 1 r9 38.3 k ? , 1%, 1/8 w size any 33 1 r10 10 k ? , 1%, 1/8 w size any 34 1 r11 33 ? , 1/4 w , 5% an y 35 2 hs1, hs2 heatsi nk, t o -220 581 00 2b02 50 0 aavid (a lso w a kefiel d 634- 10abp) 36 2 hs1, hs2 scre w , 6- 32 5/ 16? pan he ad ph ili ps z i nc 37 2 hs1, hs2 w a sher, 6-32, z i nc 38 1 j1 hea der 0.156? sp aci n g , 3 pos 26-4 8 -10 3 1 mole x (pull mi dd le pi n ) 39 1 j2 hea der 26-4 8 -10 2 1 mole x 0.156? sp aci n g , 2 pos 40 1 ep-34 printe d circuit bo ard, rev. a 41 1 jp1-4 t i nned bus w i re, 22 aw g page 10 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 7 t r ansformer s p ecification 7.1 electrical diagram wd g #3 6t 4 x #25 awg triple ins u lated wdg #1 58t #26 awg wd g #2 5t 2 x #26 awg 9, 1 0 6, 7 1 3 5 4 figure 4 ? ep-34 tri p le in sulate d tra n sformer. 7.2 electrical specifications electrical str e ngth 1 se con d , 60 hz, from pin s 1-5 to pins 6 - 10 3000 vac primar y indu ctan ce pins 1-3, all other win d ing s open, mea s u r ed at 100 khz, 0.4 vrms 827 h, 10 % reso nan t fr equen c y pins 1-3, all other win d ing s open 750 khz (min .) primar y leakage induc ta nce pins 1-3, with pins 6-1 0 sh orted, mea s u r ed at 100 khz, 0.4 vrms 20 h (max .) 7.3 m a t e rials i t e m d e s c r i p t i o n [1] core: ef25 nippon cerami c nc-2 h mat e rial o r equiv a lent. gapp e d for al of 246 nh/t 2 [2] bobbin: 10 pi n ef25, vertical mou n t, miles-pl atts fe0100 with tbs-601 pi ns o r equivalent [3] magnet wire: #26 awg double coate d [4] triple in sulat ed wire: #25 awg [5] tape, 3m #4 4 or equival e nt 1.5 mm wide (min.) [6] tape, 3m #1 298 or e quiva lent 14.2 mm wide [7] tape, 3m #1 298 or e quiva lent 15.7 mm wide [8] varnis h page 11 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 7.4 transformer build diagram pins side secondar y bias margin primar y figure 5 ? ep-34 tran sformer build di a g ram. 7.5 transformer construction bobbin prep aration pull pin 8 on bobbi n [2] to provide p o lari zation. bobbi n pinout is sh own belo w . primar y margin apply 1.5 mm wide ma rgin to pin side of bobbi n usin g item [5]. match height of prim ary and bia s windi ng s. margin tape i s n eede d to mee t safety spa c in g from prima r y windi ng to co re an d core to se conda ry pins. primar y start at pin 3. wind 30 turns of item [3] in approximat ely 1 layer. bring finish lea d ba ck to sta r t. wi nd rem a ining 28 prim ary turns, fini sh on pin 1. note: thi s ?z? windin g tech nique significantly lowers p r imary capa ci tance to redu ce no -l oad po we r co nsum ption. basic insula tion use two layers of item [6] for ba sic in sul a tion. bifilar bias winding starting at pin 5, wind 5 bi filar turn s of item [3]. sprea d turns evenl y across bo bbi n. finish at pin 4. basic insula tion use one laye r of item [7] fo r basi c in sulat i on. 12 v quadrifilar seconda r y winding start at pins 9 and 10. wi nd 6 qua drifil ar turn s of item [4] (about 1.2 layers). spre ad turn s even ly acro ss b o b b in. finish o n pins 6 and 7. oute r wra p wrap win d ing s with 3 layers of tape [item [7]. core prep ar ation wrap bottom of one e core [1] with 2 layers of tap e [7] as sh own. final assem bly asse mble a n d se cure co re halves so that the tape wrappe d e core is at the bottom of the tran sform e r. varni s h impre gnate (it e m [8]). 7.6 transformer sources for information on the vendors used to source the transformers used on this board, please v i sit the power integrations' web site at the url below and select ?engineerin g prototype boards?. http://www.powerint.com/ componentsuppliers.htm page 12 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 8 t r ansformer s p readsheet s pow e r suppl y input vacmin volts 85 min input ac voltage vacmax volts 265 max input ac voltage fl hert z 50 ac main fre quen cy tc mseco n d s 2.21 bridge re ctifier co ndu ctio n time estim a te z 0.49 loss allocation fact or n % 80.0 e f f i c i e n c y est i m a t e pow e r suppl y outputs v o x v o l t s 12.00 9.00 o u t p u t voltag e i o x a m p s 2.500 0.010 o u t p u t cu rre n t v b v o l t s 15.00 b i a s voltage i b a m p s 0.006 b i a s cu r r e n t device var i ables d e v i c e top245y/f d e v i c e nam e p o w a t t s 30.18 total o u t p u t powe r vdrain volts 647 maximum drain voltage e s timate (in c lu des effect of leakage in ducta nce) vds volts 5.2 d evice on-st a te drai n to source voltag e fs hert z 1320 00 device switching frequ en cy krpkdp 0.40 rippl e to peak cu rrent rat i o ki 0.70 external cu rrent limit ratio i l i m i t e x t a m p s 1.17 device cu rrent limit external minimum ilimitmin amps 1.67 device current limit minimum ilimitmax amps 1.93 device current limit maximum ip amps 0.98 peak prim ary current irms amps 0.63 primary rms current dmax 0.63 maximum duty cycle pow e r suppl y com ponents selection cin ufarad s 68.0 i nput filter capa citor vmin volts 76 minimum dc input voltage vmax volts 375 maximum dc input voltage vclo volts 190 clamp z ene r voltage pz watts 2.5 e stimated pri m ary zene r clamp lo ss vdb volts 0.7 b ias win d ing diod e forwa r d voltage dro p pivb volts 64 bias re ctifier maximum peak inverse vo ltage pow e r suppl y output parameters vdx volts 0.5 0 .5 output win d i ng dio de fo rward voltage dro p pivsx volts 51 39 output re ctifier maximum peak inverse voltage ispx amps 9.17 0.04 peak se con d a ry cu rre nt isrmsx amps 4.52 0.02 secon d a r y rms current iripplex amps 3.77 0.02 output ca pa citor rms ri pple current page 13 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 transformer construction parameters core/bobbi n e 2 5 / 1 3 / 7 (ef 2 5 ) margi core and bo bbin type core manuf. generic core manufac t uring bobbin ma nu f gene ric bobbin ma nu facturin g l p u h e n rie s 8 2 7 p r i m a r y indu ctan c e np 58 primary wi nd ing num b e r o f turns nb 7.54 bias win d ing numb er of tu rns awg awg 27 primary wi re gaug e (roun ded to next smaller stand ard a w g value) cma cmils/a 322 primary wi nd ing cu rrent capa city vor volts 120.00 refle c ted out put voltage bw mm 15.30 bobbin physi c al wi ndin g width m mm 1.0 safety margin width l 2.0 numb er of primary layers ae cm^2 0.53 core effective cro s s secti on area alg nh/t^2 249 gapp ed core effective inductan c e bm gau ss 2693 maximum op erating fl ux den s ity bp gau ss 3688 peak flux de nsity bac gau ss 539 ac flux den s ity for core curve s l g m m 0 . 2 3 g a p le n g t h ll uhe n rie s 12.4 estimated transfo rme r pri m ary lea ka g e inducta nce lsec nhe n rie s 20 estimated se con dary trace inducta nce second ar y parameters nsx 6.00 4.56 secon d a r y numbe r of turns rou nde d do wn nsx 4 r ou nde d to integer se co n dary nu mbe r of turn s rou nde d do wn vox volts 7.83 auxiliary output voltage for ro und ed to integer nsx rou nde d up nsx 5 r ou nde d to next integer secon d a r y numbe r of turn s rou nde d up vox volts 9.92 auxiliary output voltage for ro und ed to next integer nsx awgsx ran ge awg 17 - 21 40 - 44 secon d a r y wire gau ge ra nge comm ent: primary wire ga uge is le ss than recomme nde d minimum (2 6 awg) a nd may overhe at tip: con s ide r a parallel win d ing techniq u e (bifilar, trifilar), increase si ze of tra n sformer (larger bw) or redu ce m a rgi n (m). comment: wire page 14 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 9 performance dat a all measur ements performed at room temperature, 60 hz input frequency. 9.1 efficiency ep-34 efficiency v s . input voltage 70% 75% 80% 85% 90% 95% 100% 80 100 120 140 160 180 200 220 240 260 280 a c i nput vol t age efficiency (%) iout = 2.5 a iout = 1 a figure 6 - efficien cy vs. input voltage, room t e mpe r ature, 60 hz. 9.2 no-load input power ep- 34 zer o load i nput pow e r v s . i nput vol t age 0. 2 0. 25 0. 3 0. 35 0. 4 0. 45 0. 5 85 105 125 145 165 185 205 225 245 265 a c i nput vol t a g e input power (w) figure 7 - ze ro loa d input power vs. in put line volta ge, room t e mperature, 6 0 hz. page 15 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 9.3 regulation 9.3.1 load e p -34 lo a d regu lation 95 % 96 % 97 % 98 % 99 % 10 0% 10 1% 10 2% 10 3% 10 4% 10 5% 01 23 o u tput load (a ) regulation (% of nominal) 8 5 vac 11 5 v a c 23 0 v a c 26 5 v a c figure 8 ? ep-34 lo ad regulatio n, ro om tempe r at ure. 9.3.2 line ep-34 line regulation, full load 95% 96% 97% 98% 99% 100% 101% 102% 103% 104% 105% 80 100 120 140 160 180 200 220 240 260 280 a c input voltage regulation (% of nominal) figure 9 ? ep-34 lin e re gulation, roo m tempe r atu r e, full loa d. page 16 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 9.4 overload power the curve below shows the maximum overload pow er vs. input line voltage. the x pin of u1 is used to reduc e the primary current limit with increasing line volt age, limitin g overload power. ov er load pow e r v s line voltage 100 110 120 130 140 150 160 170 180 190 200 80 100 120 140 160 180 200 220 240 260 280 i nput vol t age ( v a c ) overload power (% of 30 w) figure 10 ? ep-34 overl o ad powe r vs. line voltage, room t e mpe r ature. page 17 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 10 thermal performance all measur ements were made wit h the unit operating o pen frame i n still air with a load of 30 w. the results show adequate thermal ma rgin, the worst case being low line and 50 c ambient. note: the thermal image does not correctl y i ndicate the temperature of the capacitors due to their shiney top surface. tempera t ure ( c) item 85 vac 115 vac 230 vac 85 vac 115 vac 230 vac am bient 2 9 2 8 2 8 5 0 5 0 5 2 balun (l 1) 5 4 4 3 3 6 8 2 7 4 6 6 bridge ( b r1) 6 3 4 9 4 3 9 2 8 3 7 3 trans f ormer (t1) 6 2 5 9 6 5 8 9 8 7 9 0 clamp zene r (vr1) 5 5 5 5 4 8 9 7 8 9 8 5 topswitch (u 1) 6 8 5 7 5 5 1 0 6 9 1 8 6 rectifier (d3) 5 7 5 6 5 5 8 8 8 5 8 5 figure 11 - i n frared the r mograph of ep-34, 85 vac inpu t, maximum contin uo us lo ad, 22 c ambient. page 18 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 11 w aveforms 11.1 drain voltage and current, normal operation figure 12 - 8 5 vac, full load. upp e r: i drain , 0.5 a/div. lower: v drain , 100 v, 2 s/ div . figure 13 - 2 65 vac, full load. upp e r: i drain , 0.5 a /div. lower: v drain , 200 v, 2 s/ div . 11.2 output voltage start-up profile figure 14 - s t art-up profile , 115 vac. 2 v, 20 ms/div. figure 15 - s t art-up profile , 230 vac. 2 v, 20 ms/div. 11.3 drain voltage and current start-up profile figure 16 - 8 5 vac input and maximu m load. upp e r: i drain , 0.5 a/div. lower: v drain , 100 v, 1 ms/div. figure 17 - 2 65 vac input and maximu m load. upp e r: i drain , 0.5 a /div. lower: v drain , 200 v, 1 ms/div. page 19 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 11.4 load tran sient response (75 % to 100 % load step) in the figures shown below, signal averagin g was us ed to better enable viewing the load transient response. the osc illoscope was triggered using the l oad current step as a trigger source. since the out put switching and line frequency occur essentially at random with respect to the load transient, contributi ons to the output rippl e from these sources will av erage out, leaving the contributi on only from the load-step respons e. figure 18 ? ep-34 transi ent re spo n se, 115 vac, 75%-1 00%-7 5% load ste p . top: load cu rre nt, 1 a/div. bottom: output voltage. 50 mv, 500 s/ div . figure 19 ? ep-34 transi ent re spo n se, 230 vac, 75%-1 00%-7 5% load ste p upp e r: loa d curre n t, 1 a/div. bottom: output voltage. 50 mv, 2 ms/div. page 20 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 11.5 output ripple m easurements 11.5.1 ripple measurement technique for dc out put ripple measurements, a modifi ed osc i lloscope tes t probe must be utiliz ed in order to reduce spurious signals due to pi ckup. det a ils of the probe modification are provided in figur e 19 and figure 20. the 5125ba probe ad apter is affixed with two capac itor s tied in parallel acros s 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 alu m inum electrolytic type capacitor is polarized, so proper polarity across dc outputs must be maintained (see below). probe ground probe tip figure 20 - o scill osco pe probe prepa re d for rippl e meas urement (end ca p an d grou nd le a d remove d). figure 21 - o scill osco pe probe with pro be maste r 51 25ba bnc a dapter (modifi ed with wi re s for pro be grou nd for ri p p le mea s u r e m ent, and two parall e l de couplin g cap a c itors add ed ). page 21 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 11.5.2 measurement results figure 22 - ripple, 85 vac, full load. 2 ms, 50 mv / div. figure 23 - 5 v ripple, 11 5 vac, full load. 2 ms, 50 mv / div. figure 24 - ripple, 230 va c, full load. 2 ms, 50 mv /div. page 22 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 12 control loop me asurement s 12.1 115 vac m a ximum load figure 25 - g a in-ph a se plot, 180 vac, maximum steady state load. vertical scale : gain = 10 d b /div, phase = 50 /div. cro s sove r freque ncy = 1. 16 khz pha s e margi n = 6 6 .5 12.2 230 vac m a ximum load figure 26 - g a in-ph a se plot, 230 vac, maximum steady state load. vertical scale : gain = 10 d b /div, phase = 50/div. cro s sove r freque ncy = 8 3 1 hz, pha s e margi n = 79. 4 page 23 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 13 conducted emi figure 26 - condu cted em i, maximum steady state load, 115 va c, 60 hz, and en5502 2 b limits. figure 27 - condu cted em i, maximum steady state load, 230 va c, 60 hz, and en5502 2 b limits. page 24 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 14 ac surge and 100 khz ring w ave immunity four series of line transient tests were per formed on the ep-34 to de termine the level of immunity attainable for the basic board. te s t ing was performed us ing a keytek emc pro surge generator. the input voltage for th e supply under test was 230 vac, and the supply was loaded to the maxi mum continuous output power using a resistive load. an led was used to monitor t he presence of out put volt age and to detect output interruptions. the secondary return was hard wired to the safety ground at the surge generator. this is a worst-case test condi tion for common mode surge and ring wave testing, and the test results reflect this. if surge tests are conduc ted without this ground connection, the common mode surge/ring wave withs tand is highe r. test for each series was terminated upon non-dest r uctive int e rrupt ion of output v o ltage, arc i ng, or no n- recoverable interruption of output voltage. a test fa ilure was defined as a non- recoverable interruption of out put voltage requiring supply r epair or recycling of input ac voltage. 14.1 common m o de sur g e, 1.2/50 s surge voltage phase angle ( ) gener a tor impedance num b er o f strikes test resul t 1 kv 0 12 ? 1 0 p a s s 1 kv 90 12 ? 1 0 p a s s 1 kv 270 12 ? 1 0 p a s s 2 kv 0 12 ? 1 0 p a s s 2 kv 90 12 ? 1 0 p a s s 2 kv 270 12 ? 1 0 p a s s 3 kv 0 12 ? 1 0 p a s s 3 kv 90 12 ? 1 0 p a s s 3 kv 270 12 ? 1 0 p a s s 4 kv 0 12 ? 10 pass (1 power interruption/1 0 stri ke s, r e covered) 4 kv 90 12 ? 10 pass (2 power interruption s / 10 stri ke s, r e covered) 4 kv 270 12 ? 1 pass (4 power interruption s / 10 stri ke s, r e covered) page 25 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 14.2 differential m ode sur g e, 1.2/50 s surge voltage phase angle ( ) gener a tor impedance num b er o f strikes test resul t 1 kv 0 12 ? 1 0 p a s s 1 kv 90 12 ? 1 0 p a s s 1 kv 270 12 ? 1 0 p a s s 2 kv 0 12 ? 1 0 p a s s 2 kv 90 12 ? 1 0 p a s s 2 kv 270 12 ? 1 0 p a s s 3 kv 0 12 ? 1 0 p a s s 3 kv 90 12 ? 1 0 p a s s 3 kv 270 12 ? 1 0 p a s s 4 k v 0 12 ? 1 0 p a s s 4 kv 90 12 ? 1 0 p a s s 4 kv 270 12 ? 1 0 p a s s 14.3 common m o de, 100 khz ring wave surge voltage (kv) phase angle ( ) short circ uit curre nt num b er o f strikes test resul t 1 kv 0 500 a 10 pass 1 kv 90 500 a 10 pass 1 kv 270 500 a 10 pass 2 kv 0 500 a 10 pass 2 kv 90 500 a 10 pass 2 kv 270 500 a 10 pass 3 kv 0 500 a 10 pass (6 interruptions /10 st ri kes, r e c o v e red ) 3 kv 90 500 a 10 pass (7 interruptions /10 st ri kes, r e c o v e red ) 3 kv 270 500 a 10 pass (6 interruptions /10 st ri kes, r e c o v e red ) 14.4 differential m ode, 100 khz ring wave surge voltage phase angle ( ) short circ uit curre nt num b er o f strikes test resul t 1 kv 0 500 a 10 pass 1 kv 90 500 a 10 pass 2 kv 270 500 a 10 pass 2 kv 0 500 a 10 pass 2 kv 90 500 a 10 pass 3 kv 270 500 a 10 pass 3 kv 0 500 a 10 pass 3 kv 90 500 a 10 pass 3 kv 270 500 a 10 pass 4 kv 0 500 a 10 pass 4 kv 90 500 a 10 pass 4 kv 270 500 a 10 pass page 26 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
10-feb-2004 EPR-34 ? 12 v, 30 w, universal input 15 revision history date author revision description & chang es 2 8 - j a n - 0 3 r h 0 . 1 f i r s t d r a f t 0 3 - f e b - 0 3 r h 0 . 2 s e c o n d d r a f t 2 1 - f e b - 0 3 r h 0 . 3 t h i r d d r a f t 2 1 - a p r - 0 3 r h 1 . 0 first r e l e a s e 10-feb-04 km 1.1 second release ? transformer specification on page 11 corrected (primary inductance, resonant frequency and alg). page 27 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-34 ? 12 v, 30 w, univ ersal input 10-feb-2004 for t h e l a t e s t up d a t e s , v i s i t our w e b s i t e : w w w . po w e r i nt . c o m p o w e r i n t e g r at i o ns m a y m a k e c han ges t o i t s p r od uc t s a t a n y t i m e . p o w e r i n t e gr at i o n s h a s n o l i ab i l i t y a r i s i n g f r om y o ur us e of an y i n f o r m at i o n, de v i c e o r c i r c ui t des c r i bed he r e i n no r do e s i t c o n v e y a n y l i c e n s e un d e r i t s p a t e nt r i ght s o r t he r i g h ts of oth e r s . p o w e r i n t e g r a t io n s m akes n o w a r r a n t i e s h e r e in an d spe c i f i c a l l y d i sc l a im s al l w a rr a n t i e s i ncl ud i n g , w i t h o u t l i m i t a t i o n , t h e i m p l i e d w a rr a n t i e s o f m e rcha n t a b i l i t y , f i t n ess f o r a par t i c u l a r p u r p o se, a n d n o n - in f r i n g e m e n t o f t h i r d pa r t y r i g h t s . p a t e nt i n fo rm a t i o n t h e p r od uc t s an d a p pl i c at i o n s i l l u s t r a t ed h e r e i n ( i n c l u di n g c i r c u i t s e x t e r n al t o t h e p r odu c t s an d t r an s f o r m e r c o n s t r u c t i on) m a y b e c o v e red b y o n e o r m o r e u . s . an d f o r e i g n pa t ent s or po t e n t i a l l y b y pe ndi ng u . s . an d f o r e i g n pat e n t a p pl i c a t i o n s a s s i gn ed t o p o w e r i n t e gr a t i o ns . a c o m p l e t e l i s t o f p o w e r i n t e g r at i o n s ? pat ent s m a y be f o u nd a t w ww. p o we ri n t . c o m . t h e p i l o go, to p s w i t c h , ti n y sw i t c h , li nk s w i t ch , and e cos m a r t ar e r egi s t e r ed t r ad em a r k s of po w e r inte g r a t i o n s . p i e xpe r t and dp a - s w i t c h ar e t r ad em a r k s of p o w e r i n t e g r at i o ns . ? c o py r i gh t 20 04, p o w e r i n t e g r at i o ns . wo r l d he ad q u art e r s po w e r i n t e g r a t i o n s 52 45 h e l l y e r a v e n u e s a n j o s e , c a 95 13 8, u s a . m a i n : + 1 -40 8 - 4 1 4 -9 20 0 cu s t o m e r s e r v i c e : p h o ne: + 1 - 4 0 8 -4 1 4 - 9 6 6 5 f a x : + 1 -40 8 - 4 1 4 -9 76 5 e-m a i l : us as a l e s @ p o w eri n t . c o m ch i n a (s he n z he n ) po we r i n te g r a t i o n s in te r n a t i o n a l h o l d i n g s , in c . r m # 1 7 05 , b a o hu a b l d g . 10 16 h u a qi a n g b e i l u s h en z h en gu an gd o n g , 51 80 3 1 , c h i n a p h o n e: + 8 6 - 7 5 5 - 8 3 6 7 - 5 14 3 f a x: + 8 6 - 75 5- 8 3 7 7 - 9 6 1 0 e - m a i l : c h i n asa l es @ p o w e r i n t . c o m it al y p o w e r i n t e gr a t i o n s s . r. l . vi a v i tto r i o v e n e to 1 2 , br e s so m i l a n o , 20 09 1, i t a l y p h o n e: + 3 9- 0 2 8 - 9 2 8 - 60 01 f a x : + 3 9- 02 8- 9 2 8 - 60 09 e- m a i l : e u ro sal e s @ p o we ri n t . c om s i ng ap o r e ( a s i a p a c i f i c he a d q u art e r s ) p o w e r i n t e g r at i o n s , s i ng ap o r e 5 1 ne wt o n ro a d # 1 5 - 0 8 / 1 0 g o l d hi l l p l az a s i n g a p o r e , 30 89 0 0 p h o n e : + 6 5 - 63 58 - 2 1 6 0 f a x: + 6 5 - 63 58 - 2 0 1 5 e- m a i l : s i ng ap or e s a l es @ p ow e r i n t . c o m am e r i c as po w e r i n t e g r a t i o n s 43 35 s o u t h l ee s t r e e t , su i t e g b u f o r d , ga 3 0 51 8, u s a p h o ne: + 1 - 6 7 8 -7 1 4 - 6 0 3 3 f a x : + 1 -67 8 - 7 1 4 -6 01 2 e-m a i l : us as a l e s @ p o w eri n t . c o m ge r m a n y p o w e r in t e g r a t i o n s , g m b h ru e c k e rt s t ra s s e 3 d- 80 33 6, m u e n c h e n , g e r m a n y p h o n e : + 4 9 - 8 9 - 5 52 7- 3 9 1 0 f a x : + 4 9 - 8 9 - 5 52 7- 3 9 2 0 e - m a il : e u r o s a le s @ p o w e r i n t . c o m j a p an po w e r i n te g r a t i o n s , k.k. k e ih in - t a t e m o n o 1 s t b l d g . 12 - 2 0 s h i n - y o k o h a m a 2- c h o m e , k o h o k u - k u, y o k o h a m a - s hi , k a na ga w a 2 2 2 - 0 0 3 3 , j a p a n p h o n e : + 8 1- 4 5 - 4 7 1 - 1 02 1 f a x : + 8 1- 4 5 - 4 7 1 - 3 71 7 e- m a i l : j a pa ns a l e s @ p ow e r i n t . c o m t a i w an po we r i n te g r a t i o n s in te r n a t i o n a l h o l d i n g s , in c . 5 f - 1 , n o . 3 1 6 , n e i h u r d . , se c . 1 ne i h u di s t . t a i p ei , t a i w a n 1 1 4, r . o . c . p h o n e : + 8 8 6 - 2 - 2 65 9- 4 5 7 0 f a x : + 8 8 6 - 2 - 2 65 9- 4 5 5 0 e- m a i l : t a i w an s a l e s @ po w e r i n t . c o m c h i n a ( s ha ng ha i ) po w e r i n t e g r a t i o n s in te r n a t i o n a l h o l d i n g s , in c . r m 80 7 , p a c h ee r co m m e r c i a l ce nt re 55 5 n a n j i n g w e s t ro ad s h an gh ai , 2 0 0 0 4 1 , ch i n a p h o ne: + 8 6 - 2 1 -6 2 1 5 - 5 5 48 f a x : + 8 6 - 2 1 - 6 21 5- 2 4 6 8 e-m a i l : c h i n a s al es @ p o w e r i n t . c om in d i a ( t e c h n i c al su p p o r t ) in n o v a te c h 26 1/ a , g r o u n d f l o o r 7t h m a i n , 1 7 t h c r o s s , s a da s h i v an ag ar b a n g al or e 56 00 8 0 p h o n e: + 9 1- 8 0 - 5 1 1 3 - 80 20 t e l e f a x : + 9 1- 8 0 - 5 11 3- 802 3 e - m a i l : i n di a s al es @ p o w e r i n t . c o m ko r e a po w e r i n te g r a t i o n s in te rn a t i o n a l h o l d i n g s , in c . 8t h f l o o r , d o n g s u n g b l d g . 1 7 -8 y o i d o - do ng , y o un g d e u ng po - g u , s e o u l , 15 0- 8 7 4 , k o r e a p h o n e : + 8 2- 2 - 7 8 2 - 28 40 f a x : + 8 2- 2 - 7 8 2 - 44 27 e- m a i l : k o r e as al e s @ p o w e r i n t . c o m uk (e ur o p e & af r i c a he a d q u art e r s ) p o w e r i n t e g r a t i o n s ( e u r op e) lt d. 1 st fl o o r , s t . j a m e s ? s h o u s e ea s t st r e e t fa r n h a m su r r e y gu 9 7t j u n i t e d k i ng do m p h o n e : + 4 4 (0 ) 1 2 5 2 - 7 30 -1 4 0 f a x : + 4 4 (0 ) 1 2 5 2 - 7 27 -6 8 9 e - m a il : e u r o s a le s @ p o w e r i n t . c o m a p pl ic a t i o n s h o t l i n e w o r l d wi de + 1 - 4 0 8 -4 14 - 9 6 60 ap p l i c at i o n s f a x w o rl d w i d e + 1 -4 08 - 4 1 4 -9 76 0 page 28 of 28 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m

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