DER-107 EFD20 CISPR22B EN55022B IEC950 UL1950 DFS06 KMG50VB10RM5X11LL DO-35

Title 10W Compact Power Supply using TOP245R Specification Input: 90 300 VAC Output: 6V / 1.67A Application Water Purifier

Design Example Report Title 10W Compact Power Supply using TOP245R Specification Input: 90 300 VAC Output: 6V / 1.67A Application Water Purifier Author Power Integrations Applications Department Document Number DER-107 DER-107 Date October 26, 2005 Revision 1.0 Summary and Features · · · · · · · 66kHz operation to reduce switching losses in TOPSwitch-GX, reduce standby power consumption and reduce burden on input EMI Filter Low profile EFD20 EFD20 ESHEILD transformer construction Simple input -filter No Y-cap No X-cap 450 VDC input capacitors for increased reliability for continuous 300 VRMS operation No heat sink design - D2PAK TOPSwitch-GX and D-PAK output rectifier 10 W (continuous) / 18 W (peak) in 1.6 X 2.5 X 1" The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 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. 6 5 PCB Layout . 7 6 Bill Of Materials . 8 7 Transformer Specification. 9 7.1 Electrical Diagram . 9 7.2 Electrical Specifications. 9 7.3 Materials. 9 7.4 Transformer Build Diagram . 10 7.5 Transformer Construction. 10 8 PIXL Transformer Spreadsheet. 11 9 Performance Data . 15 9.1 Efficiency. 15 9.2 No-load Input Power. 15 9.3 Regulation . 16 9.3.1 Load . 16 9.3.2 Line . 16 10 Waveforms. 17 10.1 Drain Voltage and Current, Normal Operation . 17 10.2 Output Voltage Start-up Profile at Full Load. 17 10.3 Drain Voltage and Current Start-up Profile. 18 10.4 Load Transient Response (Load Step). 19 10.5 Output Ripple Measurements. 20 10.5.1 Ripple Measurement Technique . 20 10.5.2 Measurement Results . 21 11 Control Loop Measurements. 22 11.1 120 VAC Maximum and 3A Load . 22 11.2 240 VAC Maximum and 3A Load . 23 12 Conducted EMI . 24 13 Revision History . 25 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. Page 2 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 1 Introduction This document is an engineering report describing a universal input 6 V / 10 W power supply utilizing a TOP245R. This power supply is intended to be used in a compact adapter for a water purification application. This supply has been design to operate at 300 VAC input continuously as well as provide a peak output current of 3 A for two minutes. The document contains the power supply specification, schematic, bill-of-materials, transformer documentation, printed circuit layout, and performance data. Top Bottom Figure 1 Populated Circuit Board Photograph Page 3 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 2 Power Supply Specification Description Input Voltage Frequency No-load Input Power (240 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Peak Output Power Efficiency Symbol Min Typ Max Units Comment VIN fLINE 90 47 300 64 0.5 VAC Hz W 2 Wire no P.E. 50/60 VOUT1 VRIPPLE1 IOUT1 POUT POUT_PEAK 6 100 1.67 V mV A 10 18 75 W W % ± 5% 20 MHz bandwidth 2 minute duration Measured at POUT (10 W), 25 oC Environmental Conducted EMI Meets CISPR22B CISPR22B / EN55022B EN55022B Designed to meet IEC950 IEC950, UL1950 UL1950 Class II Safety Surge 4 kV Surge 4 kV Ambient Temperature Page 4 of 26 TAMB 0 40 o C 1.2/50 µs 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 3 Schematic Figure 2 Schematic Page 5 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 4 Circuit Description The schematic in Figure 2 shows an off-line Flyback converter using the TOP245R. The circuit is designed for 90 VAC to 300 VAC input and 6 V, 1.67 A output, with a transient load requirement of 3 A for 2 minutes in duration. 4.1 Input EMI Filtering Capacitor C1, C2 and L1 form in input p-filter for differential-mode conducted EMI. Common-mode conducted EMI is reduced with the ESHIELD winding technique employed in the transformer construction. A input X-capacitor and a Y-capacitor to bridge the isolation barrier are not required, due to the ESHIELD transformer construction and frequency dithering of the TOPSwitch-GX. 4.2 TOPSwitch Primary Rectifier bridge BR1 and C1, C2 provide a high voltage DC BUS for the primary circuitry. The DC rail is applied to the primary winding of T2. The other side of the transformer primary is driven by the integrated MOSFET in U1. Diode D4, R7, R3 and C6 clamp leakage spikes generated when the MOSFET in U1 switches off. Resistor R8 sets the low-line turn-on threshold to approximately 69 VAC, and also sets the over-voltage shutdown level to approximately 320 VAC. R2 sets the U1 current limit to approximately 75% of its nominal value. This limits the output power delivered during fault conditions. C5 bypasses the U1 CONTROL pin. C4 has 3 functions. It provides the energy required by U1 during startup, sets the auto-restart frequency during fault conditions, and also acts to roll off the gain of U1 as a function of frequency. R1 adds a zero to stabilize the power supply control loop. Diode D3 and C12 provide rectified and filtered bias power for U3 and U1. The Frequency pin (F-pin) of U1 is tied to the Control pin (C-pin) to set the operating frequency of the U1 to 66kHz. 4.3 Output Rectification The output of T2 is rectified and filtered by D6, C9, and C10. Inductor L2 and C11 provide additional high frequency filtering. 4.4 Output Feedback Resistors R9 and R10 divide down the supply output voltage and apply it to the reference pin of error amplifier U2. Shunt regulator U2 drives optocoupler U3 through resistor R12 to provide feedback information to the U1 CONTROL pin. The optocoupler output also provides power to U1 during normal operating conditions. Components C4, C13, R1, R11, and R12 all play a role in compensating the power supply control loop. Capacitor C4 rolls off the gain of U1 at relatively low frequency. Resistor R1 provides a zero to cancel the phase shift of C4. Resistor R12 sets the gain of the direct signal path from the supply output through U2 and U3. Components C13 and R11 roll off the gain of U2. Page 6 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 5 PCB Layout Figure 3 Printed Circuit Layout Page 7 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 6 Bill Of Materials Item QTY Ref Des Description 1 1 BR1 600 V, 1 A, Bridge Rectifier, SMD, DFS C1 C2 22 uF, 450 V, Electrolytic, 105C (16 x 25) Value Mfg Mfg Part Number DFS06 DFS06 Vishay DFS06 DFS06 2 2 3 1 4 2 5 1 6 2 7 1 C11 100 uF, 10 V, Electrolytic, Low ESR, 500 mOhm, (5 x 11.5) 8 1 C12 10 uF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) 10 uF United Chemi-Con KMG50VB10RM5X11LL KMG50VB10RM5X11LL 9 1 D3 200 V, 300 mA, Fast Switching, DO-35 DO-35 BAV21 BAV21 Vishay BAV21 BAV21 S1M C4 47 uF, 16 V, Electrolytic, Gen. Purpose, (5 x 11) C5 C13 100 nF, 50 V, Ceramic, X7R C6 2.2 nF, 1 kV, Disc Ceramic C9 C10 560 uF, 25 V, Electrolytic, Very Low ESR, 29 mOhm, (8 x 20) 22 uF Nichicon UVZ2W220MHD UVZ2W220MHD 47 uF United Chemi-Con KME16VB47RM5X11LL KME16VB47RM5X11LL 100 nF Panasonic ECU-S1H104KBB ECU-S1H104KBB 2.2 nF NIC Components Corp NCD222K1KVY5F NCD222K1KVY5F 560 uF Rubycon 1EZLH560K8X20 1EZLH560K8X20 100 uF United Chemi-Con LXZ10VB101ME11LL LXZ10VB101ME11LL 10 1 D4 1000 V, 1 A, Rectifier, Glass Passivated, SMA S1M Vishay 11 1 D6 60 V, 6 A, Schottky, SMD, DPAK 6CWQ06 6CWQ06 IR 6CWQ06 6CWQ06 12 1 F1 3.15 A, 250V, Slow, TR5 FUSE Wickman 3821315041 13 1 L1 1000 uH, 0.28 A 1mH Tokin SBC3-102-281 SBC3-102-281 14 1 L2 3.3 uH, 5.5 A, 8.5 x 11 mm 3.3uH Toko R622LY-3R3M R622LY-3R3M 15 1 R1 6.8 R, 5%, 0805 6.8 Yageo RSF200JB-200K RSF200JB-200K 16 1 R2 13.7 k, 1%, 0805 13.7 k 17 1 R3 200 k, 5%, 1 W, Metal Oxide 200 k 18 1 R7 75 R, 5%, 1/8 W, Metal Film, 0805 75 19 1 R8 2.2 M, 5%, 1/4 W, Carbon Film 2.2 M 20 1 R9 6.65 k, 1%, 1/4 W, Metal Film, 1206 6.65 k 21 1 R10 4.75 k, 1%, 1/4 W, Metal Film, 1206 4.75 k 22 1 R11 3.3 k, 5%, 1/8 W, Metal Film, 0805 3.3 k 23 1 R12 100 R, 1%, 1/8 W, Metal Film, 0805 100 24 1 RV1 300 V, 23 J, 7 mm, RADIAL VARISTOR Littlefuse 25 1 T2 Bobbin, EFD20 EFD20, Horizontal, 8 pins BEFD20 BEFD20_8P/Yih-Hwa Enterprises YW-272-03B YW-272-03B 26 1 U1 TOPSwitch-GX, TOP245R, TO-263-7C TOP245R TOP245R 27 1 U2 2.495 V Shunt Regulator IC, 1%, -40 to 85C, SOT23 LM431 LM431 National Semiconductor LM431BCM LM431BCM 28 1 U3 Opto coupler, 35 V, CTR 80-160%, 4-DIP PC817A PC817A Isocom, Sharp ISP817A ISP817A, PC817X1 PC817X1 Page 8 of 26 Power Integrations V300LA4 V300LA4 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 7 Transformer Specification 7.1 Electrical Diagram Figure 4 Transformer Electrical Diagram 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 1 second, 60 Hz, from Pins 1-4 to Pins 5-8 Pins 3-4, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 3-4, all other windings open Pins 3-4, with Pins 5-8 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 606 µH, -7/+7% 800 kHz (Min.) 100 µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description 2 Core: EFD20/3F3 EFD20/3F3 AL = 104nH/T Bobbin: 8-pin Magnet Wire: #35 AWG Heavy Build Magnet Wire: #27 AWG Heavy Build Tape: 3M 3mm wide Tape, 3M Tape, 3M Copper tape 1.5 mil thick X 8mm wide Varnish Page 9 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 7.4 10 W Compact Power Supply October 26, 2005 Transformer Build Diagram Figure 5 Transformer Build Diagram 7.5 Transformer Construction Bobbin Preparation Primary Margin Primary Basic Insulation Bias Winding Basic Insulation Primary Margin Balanced Shield Winding Reinforced Insulation Secondary Margin Secondary Winding Outer Wrap Core Preparation Outer Belly band Final Assembly Page 10 of 26 Align bobbin to have pins 1-4 facing the mandrill Apply 3 mm wide margin on either side of bobbin with item [5]. Match height of primary and bias windings. Start at Pin 3. Wind 76 turns of item [3] in approximately 2 layers, finish on Pin 4. Use one layer of item [6] for basic insulation. Starting at Pin 2, wind 14 turns of item [3] uniformly across bobbin width in a single layer. Finish at Pin 1. Use one layer of item [6] for basic insulation. Apply 3 mm wide margin on either side of bobbin with item [5]. Match height of balanced shield winding. Start temporarily on pin 6. Wind 4 turns of quadrifilar item [4] uniformly across the bobbin width in a single layer. Finish on pin 4. Cut start of winding at 90-degree bend to center of bobbin window. Use three layers of item [7] for reinforced insulation. Apply 3 mm wide margin on either side of bobbin with item [5]. Match height of secondary winding. Start at Pin 5. Wind 6 trifilar turns of item [4]. Spread turns evenly across bobbin in a single layer. Finish on Pin 8. Wrap windings with 3 layers of tape (item [7]). Affix cores (item [1]) with tape [5]. Wrap one turn of copper tape [8] around outer core. Ensure copper tape makes contact with core halves. Solder wire from pin 2 of bobbin to copper bellyband. Wrap three layers of tape [7]. Varnish impregnate (item [9]). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-107 DER-107 10 W Compact Power Supply October 26, 2005 8 PIXL Transformer Spreadsheet ACDC_TOPSwitchGX_113004; Rev.2.2; Copyright Power Integrations Inc. 2004 INPUT INFO OUTPUT ENTER APPLICATION VARIABLES VACMIN 85 VACMAX 300 fL 50 VO 6 PO 18 n 0.73 Z 0.5 VB 15 tC 3 CIN UNIT Volts Volts Hertz Volts Watts TOP_GX_FX_113004.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet uFarads Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Bias Voltage Bridge Rectifier Conduction Time Estimate Input Filter Capacitor Universal 60W 115 Doubled/230V 85W Volts mSeconds 44 ENTER TOPSWITCH-GX VARIABLES TOP-GX TOP245 Chosen Device KI TOP245 Power Out 0.8 ILIMITMIN 1.296 Amps ILIMITMAX 1.584 Amps 66000 Hertz fSmin 61500 Hertz fSmax 70500 Hertz Frequency (F)=132kHz, (H)=66kHz fS h VOR VDS 82 10 Volts Volts VD 0.5 Volts VDB 0.7 Volts KP 0.9415 External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI