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Design Example Report
Title Specification Application Author Document Number Date Revision 42W, 4 Output Supply using TOP245Y Input: 230 VAC Outputs: 5V/4A, 6.8V/1.8A, 12V/0.8A, -10V/0.1A Set Top Box w/Hard Drive Power Integrations Applications Department DER-36 April 27, 2004 1.0
Summary and Features * * * * * High Efficiency (81% min) Low Parts Count Low Output Ripple Meets Conducted CISPR22B EMI with Margin Small Transformer (EER35)
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-36
42W, 4 Output Set Top Box Supply
April 27, 2004
Table Of Contents
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......................................................................................... 10 7.1 Electrical Diagram ............................................................................................. 10 7.2 Electrical Specifications..................................................................................... 10 7.3 Materials............................................................................................................ 11 7.4 Transformer Build Diagram ............................................................................... 11 7.5 Transformer Construction.................................................................................. 12 8 Transformer Spreadsheets....................................................................................... 13 9 Performance Data .................................................................................................... 17 9.1 Thermal Performance........................................................................................ 17 10 Waveforms............................................................................................................ 18 10.1 12V Output Turn Off .......................................................................................... 18 10.2 5V Transient Response..................................................................................... 19 11 Conducted EMI ..................................................................................................... 20 12 Revision History.................................................................................................... 22 Important Note: 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 isolation transformer to provide the AC input 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. 1 2 3 4
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
1 Introduction
This document is an engineering report describing a 230VAC input, 4 output supply power supply utilizing a TOP245Y. This power supply is intended for use in a set top box. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
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 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Output Voltage 3 Output Ripple Voltage 3 Output Current 3 Output Voltage 4 Output Ripple Voltage 4 Output Current 4 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 180 47
Typ
Max 265
Units VAC Hz W V mV A V mV A V mV A V mV A W W %
Comment
2 Wire - no P.E.
50 0.3
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 POUT POUT_PEAK
4.75 1 6.12 1.2 10.8 0.2 -9
5.00 2.5 6.80 1.5 12.0 0.8 -10 0.05
5.25 50 4 7.48 50 1.8 13.2 50 2.5 -11 50 0.10 41.8 52.7
5% 20 MHz Bandwidth 10% 20 MHz Bandwidth
10% 20 MHz Bandwidth
10% 20 MHz Bandwidth
80
Measured at POUT (42 W), 25 oC
4
kV
Surge Ambient Temperature TAMB
3 0 60
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-36
42W, 4 Output Set Top Box Supply
April 27, 2004
3 Schematic
Figure 1 - Schematic.
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
4 Circuit Description
4.1 Input EMI Filtering Components L5, L8, L10, C4, and C10 provide EMI filtering, while L4, L5, L10, SG1, and RV1 provide line surge protection. 4.2 TOPSwitch Primary Components D2, R1-2, and C5 comprise an RCD clamp with damping to limit the primary leakage spike. Use of a normal recovery diode in this clamp circuit allows some leakage energy to be recycled. Capacitors C16 and C19 bypass the U2 control pin. Components C19 and R9 also provide frequency compensation for U2. Resistor R8 sets the U2 current limit to 90% of its nominal value. 4.3 Output Rectification Output rectification and filtering is provided by D4 and C8-9 for the 5V output, D1 and C7 for the 6.8V output, D3 and C2 for the 12V output, and D7 and C12 for the -10V output. Components L1, 3, L6, L7, L9, C3, C6, C13 and C15 are used for additional high frequency filtering. Ferrite bead L2 is used to center the 12V output closer to its nominal value. 4.4 Output Feedback Output feedback is provided from the 5V output. Resistors R7 and R11 program the output voltage. The output error signal is coupled back to the supply primary via R5 and U1. Capacitor C18 and 10 compensate U3, while C17 allows current through U1 during startup to prevent output overshoot. Resistor R4 discharges C17 when the supply is off.
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
5 PCB Layout
Figure 2 - Printed Circuit Layout.
Page 7 of 23
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
6 Bill Of Materials
Item Qty Part Reference 1 2 C1 C5 2 4 C2 C7 C8 C9 3 Description Cap,Cer,2200pF, 1KV, 10% Cap,Al Elect,1500uF,35V,12.5mmX35mm,LXZ Series,NIPPON CHEMI-CON Mfg Part Number Mfg
DD-222 Vishay LXZ35VB152MK35LL Nippon Chemi-Con
3 C3 C13 C15 Cap,Al Elect,100uF,25V,6.3mmX11.5mm,NHG Series,Panasonic 1 C4 1 C6 Cap,Cer,2.2nF, Y2, 250VAC Cap,Al Elect,470uF,35V,10mmX20mm,LXZ Series,NIPPON CHEMI-CON Cap,Metal Poly,0.1uF, 250/275VAC Cap,Al Elect,100uF,400V,30mmX25mm,TSED Series, Panasonic Cap,Al Elect,100uF,25V,6.3mmX11.5mm,LXZ Series,NIPPON CHEMI-CON Cap,Al Elect,1uF,50V,5mmX11.5mm,NHG Series,Panasonic Cap,Cer, 0.10 uF, 50V, X7R, 10% Cap,Al Elect,10uF,50V,5mmX11.5mm, NHG Series,Panasonic Cap,Al Elect,47uF,16V,5mmX11.5mm,NHG Series,Panasonic Rectifier Schottky 5A 60V DO-201AD Rectifier GPP 600V 1.5A DO-204 Diode,Ultrafast, 8A, 100V Diode Schottky 45V 20A TO-220AB Diode Schottky,100V 1A DO-41 Diode SGL JUNC 100V 4.0NS DO-35 FUSE T-LAG 3.15A, 250V,Slo-Blo Geound Wire Assembly AC Input Receptacle CONN HEADER 10POS(1 X10) .156 VERT TIN CONN HEADER 4POS(1 X 4) .156 VERT TIN
ECA-1EHG101
Panasonic
4 5
440LD22 Cera-Mite LXZ35VB471MJ20LL Nippon Chemi-Con
6 7
1 C10 1 C11
ECQ-U2A104ML ECO-S2GP101CA
Panasonic Panasonic
8
1 C12
LXZ25VB101MF11LL Nippon Chemi-Con
9
1 C14
ECA-1HHG010
Panasonic
10 11
2 C16 C18 1 C17
ECU-S1H104KBB ECA-1HHG100
Panasonic Panasonic
12
1 C19
ECA-1CHG470
Panasonic
13 14 15 16 17 18 19 20 21 22 23 24
1 D1 5 D2 D5 D6 D8 D10 1 D3 1 D4 1 1 1 1 1 1 D7 D9 F1 J1 J2 J3
SB560 1N5397 MUR820 MBR2045CT SB1100 1N4148
General Semiconductor Rectron ON Semiconductor General Semiconductor Diodes, Inc. Bel Fuse
HJC-028
Singatron Molex Molex
1 J4
5 L1 L3 L6 L7 Inductor,3.3uH,2.66A L11
822LY_3R3M
Toko
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DER-36
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 2 L2 3 1 1 1 1 1 1 1 1 2 1 1 1 1 L4 L5 L10 L8 L9 R1 R2 R3 R4 R5 R6 R7 R11 R8 R9 R10 RT1
42W, 4 Output Set Top Box Supply
Bead,Ferrite, 3.25X3.5 mm,43 material Inductor,40uH,Toroid LINE FILTER,10mH,1.2A Bead, Ferrite, 6.7mm X 3.5mm, 43 material Res, 10.0, 1/2W, 5%, Carbon Film Res, 100K ,1W, 5%, Metal Film Res, 4.7, 1/2W, 5%, Carbon Film Res, 10K, 1/8W, 5%, Carbon Film Res, 150, 1/8W, 5%, Carbon Film Res, 330, 1/8W, 5%, Carbon Film Res,10.0K, 1/4W, 1%, M-FILM Res,7.50K, 1/4W, 1%, M-FILM Res, 6.8, 1/8W, 5%, Carbon Film Res, 4.7K, 1/8W, 5%, Carbon Film Thermistor,5 Ohms,3 A VARISTOR 275V 75J 14MM RADIAL LA Gas Tube,470V,5kA,Axial XFMR,HORIZ,16 Pin,776uH,EER35 Core 2643001501
April 27, 2004
Fair-Rite
2743004112 CFR-50JB-10R RSF200JB-100K CFR-50JB-4R7 CFR-12JB-10K CFR-12JB-150R CFR-12JB-330R MFR-25FBF-10K0 MFR-25FBF-7K50 CFR-12JB-6R8 CFR-12JB-4K7 SCK-053 V275LA20A B88069X5740S102
1 RV1 1 SG1 1 T1 1 U1 1 U2 1 U3
TDK Fair-rite Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo THINKING ELECTRONICS Littlefuse Epcos
IC,PC817A,PHOTOCOUPLER TRAN OUT CTR 80- ISP817A 160% 4-DIP IC,TOP245Y,INT. OFF-LINE SWITCHER,60W,TO220-7C IC,TL431CLP, ADJ SHUNT REG TO-92 TOP245Y TL431CLP
ISOCOM Power Int. TI
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
7 Transformer Specification
7.1 Electrical Diagram
14 1
WDG #6 30T 26 AWG WDG #3A 3T Cu Foil 0.005" X 0.50"
15
WDG #3B 1T Cu Foil 0.005" X 0.50"
2 Primary
4
WDG #5 5T 2 X 26 AWG WDG #1 30T 26 AWG
9,10
WDG #3C 3T Cu Foil 0.005" X 0.50"
5V 11,12 13
8 6
WDG#2 7T 2 X 26 AWG
WDG #4
5T 2 X 26 AWG
Bias
-10V 16
5
Figure 3 -Transformer Electrical Diagram
7.2
Electrical Specifications Electrical strength 60 Hz 1 second, From Pins 1-6 to Pins 7-12 Primary Inductance Pins 1-4, All other windings open, 100 kHz Resonant Frequency Pins 1-4, All other windings open Primary leakage Pins 1-4, Pins 7-12 inductance shorted, 100 kHz
3000 Vac 791uH+/-10% 1.3 MHz (min) <15 uH
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
7.3
Materials Item [1] [2] [3] [4] [5} [6] [7] [8] [9] [10] Description Core: EER35, ungapped, Nippon Ceramic NC-2H material or equiv. Gap for AL of 220 nH/T2 Bobbin: EER35 Horizontal 12 pin, TDK BEER35-1116CPH or equivalent Magnet Wire: #26 AWG Solderable Double Coated Copper Foil, 0.50" X 0.005" thick Tinned Bus Wire, 24 AWG Tape: 3M Type 1298 Polyester Film or equiv. 1.03" wide Tape: 3M Type 1298 Polyester Film or equiv. 0.65" wide Tape: 3M Type 1298 Polyester Film or equiv. 0.55" wide Tape: 3M Type 44. Polyester web or equiv. 0.24" wide (min) Transformer Varnish
7.4
Transformer Build Diagram
1 2 8 1
1/2 Primary Shield
16 13 14 15 8,9 11,12
Tape
Secondaries
5 6 2 4
Bias 1/2 Primary
Figure 4 - Transformer Build Diagram.
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DER-36 7.5
42W, 4 Output Set Top Box Supply
April 27, 2004
Transformer Construction
WINDING INSTRUCTIONS: Margin Taping Apply a 0.24" margin at each side of bobbin using item [9]. Match combined height of primary and bias windings. 1/2 Primary Winding Start at pin 4. Wind 30 turns of item [3] in a single layer. Finish at pin Basic Insulation Apply one layer of tape [8] for basic insulation. Bifilar Bias Winding Start at pin 6. Wind 7 bifilar turns of item [3] uniformly in a single layer, across entire width of bobbin. Finish on pin 5. Reinforced Insulation Apply three layers of tape [6] for reinforced insulation. Margin Taping Apply a 0.24" margin at each side of bobbin using item [9]. Match combined height of secondary windings. Secondary Foil Winding Prepare a cuffed foil assembly using items [4], [5], [7], and [8]. Starting at pin 14, wind 3 turn of foil, finish at pin 15. Wind one turn of foil, finish at pins 9 and 10, Wind three remaining turns, finish at pins 11 and 12. 10 V Bifilar Winding Starting at pin 13, wind 5 bifilar turns of item [4] directly on top of the foil winding. Space turns evenly across bobbin. Finish at pin 16. Reinforced Insulation Apply three layers of tape [6] for reinforced insulation. Margin Taping Apply a 0.24" margin at each side of bobbin using item [9]. Match combined height of primary and shield windings. Shield Winding Starting at Pin 1, wind 5 bifilar turns of item [3]. Spread turns evenly across bobbin. Finish at pin 8. Basic Insulation Apply one layer of tape [9] for basic insulation. 1/2 Primary Winding Starting at pin 2, wind 30 turns of item [3] in a single layer. Finish at pin 1. Outer Insulation Apply 3 Layers of tape [6] for outer insulation Varnish Impregnate transformer using item [10]
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
8 Transformer Spreadsheets
ACDC_TOPGX_Rev1.7_082203 INPUT Copyright Power Integrations Inc. 2003 INFO INFO OUTPUT OUTPUT UNIT TOP_GX_FX_082203.xls: TOPSwitch-GX/FX Continuous/Discontinuous Flyback Transformer Design Spreadsheet Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power
ENTER APPLICATION VARIABLES VACMIN VACMAX fL VO PO n Z VB tC CIN ENTER TOPSWITCH-GX VARIABLES TOP-GX Chosen Device KI
190 265 50 5 53 0.8 0.5 12 3 100
Volts Volts Hertz Volts Watts
Efficiency Estimate Loss Allocation Factor Volts Bias Voltage mSeconds Bridge Rectifier Conduction Time Estimate uFarads Input Filter Capacitor
TOP245 TOP245 0.8 TOP245 Power Out Power Out
Universal 60W
115 Doubled/230V 85W External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Use 1% resistor in setting external ILIMIT Use 1% resistor in setting external ILIMIT Full (F) frequency option 132kHz TOPSwitch-GX Switching Frequency: Choose between 132 kHz and 66 kHz TOPSwitch-GX Minimum Switching Frequency TOPSwitch-GX Maximum Switching Frequency Reflected Output Voltage TOPSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.4 < KRP < 1.0 : 1.0< KDP<6.0)
ILIMITMIN ILIMITMAX Frequency - (F)=132kHz, (H)=66kHz fS F 132000
1.296 1.584
1.296 Amps 1.584 Amps
132000
132000 Hertz
fSmin fSmax VOR VDS VD VDB KP 110 10 0.5 0.7 0.60
124000 140000
124000 Hertz 140000 Hertz Volts Volts Volts Volts
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EER35 Core EER35 EER35 EER35_BOBBIN EER35_BOBBIN Bobbin AE 1.07 LE AL BW M 6 9.08 2770 26.1
P/N: P/N: 1.07 cm^2 9.08 cm 2770 nH/T^2 26.1 mm mm
PC40EER35-Z BEER-35-1116CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance)
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DER-36
L NS
42W, 4 Output Set Top Box Supply
2 3
April 27, 2004
Number of Primary Layers Number of Secondary Turns
DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS TRANSFORMER PRIMARY DESIGN PARAMETERS LP NP NB ALG BM BP BAC ur LG BWE OD INS
251 375
251 Volts 375 Volts
Minimum DC Input Voltage Maximum DC Input Voltage
0.31 0.26 1.20 0.72 0.49
0.31 0.26 1.20 0.72 0.49
Amps Amps Amps Amps
Maximum Duty Cycle Average Primary Current Peak Primary Current Primary Ripple Current Primary RMS Current
791 60 7 220 1482 1951 445 1871 0.56 28.2 0.47 0.06
791 uHenries 60 7 220 1482 1951 445 1871 0.56 28.2 0.47 0.06
DIA AWG
0.41 27
0.41 27
CM CMA
203 418
203 418
Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Gauss Maximum Flux Density at PO, VMIN (BM<3000) Gauss Peak Flux Density (BP<4200) Gauss AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core mm Gap Length (Lg > 0.1 mm) mm Effective Bobbin Width mm Maximum Primary Wire Diameter including insulation mm Estimated Total Insulation Thickness (= 2 * film thickness) mm Bare conductor diameter AWG Primary Wire Gauge (Rounded to next smaller standard AWG value) Cmils Bare conductor effective area in circular mils Cmils/Amp Primary Winding Current Capacity (200 < CMA < 500)
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP ISRMS IO IRIPPLE
24.07 14.38 10.60 9.72
24.07 14.38 10.60 9.72
Amps Amps Amps Amps
Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness
CMS AWGS
2876 15
2876 Cmils 15 AWG
DIAS ODS
1.45 4.70
1.45 mm 4.70 mm
INSS
1.62
1.62 mm
VOLTAGE STRESS PARAMETERS VDRAIN
626
626 Volts
Maximum Drain Voltage
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Bias Rectifier Maximum Peak Inverse Voltage
PIVS PIVB
24 55
24 Volts 55 Volts
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 5.0 2.500 IO1 PO1 VD1 0.5 NS1 ISRMS1 IRIPPLE1 PIVS1
12.50
Volts Amps 12.50 Watts Volts 3.00 3.391 Amps 2.29 Amps 24 Volts
3.00 3.391 2.29 24
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
CMS1
678
678 Cmils
AWGS1
21
21 AWG
DIAS1 ODS1
0.73 4.70
0.73 mm 4.70 mm
2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2
6.8 1.500 10.20 0.5 3.98 2.035 1.37 32
Volts Amps 10.20 Watts Volts 3.98 2.035 Amps 1.37 Amps 32 Volts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
CMS2
407
407 Cmils
AWGS2
24
24 AWG
DIAS2 ODS2
0.51 3.54
0.51 mm 3.54 mm
3rd output VO3 IO3 PO3 VD3
12.0 2.500 30.00 0.7
Volts Amps 30.00 Watts Volts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop
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DER-36
NS3 ISRMS3 IRIPPLE3 PIVS3
42W, 4 Output Set Top Box Supply
6.93 3.391 2.29 55 6.93 3.391 Amps 2.29 Amps 55 Volts
April 27, 2004
Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
CMS3
678
678 Cmils
AWGS3
21
21 AWG
DIAS3 ODS3
0.73 2.04
0.73 mm 2.04 mm
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency, unless otherwise specified. 9.1 Thermal Performance Thermal measurements were made with the power supply mounted in the chassis, using a slip-on heat sink on the TOPSwitch. A thermocouple was attached to the heat sink next to the TOPSwitch source tab using solder. Another thermocouple was soldered to a length of adhesive-backed copper tape, which was attached to the transformer. A thermocouple was taped in the center of the chassis, with the junction in free air. This thermocouple was used to measure the ambient air temperature inside the chassis. All holes in chassis were sealed with tape except ventilation holes in chassis and holes used for load and thermocouple wires. A solid cardboard sheet was used as the chassis top lid. The thermal chamber temperature outside the chassis was adjusted until the desired temperature was attained inside the chassis. Due to the limited size of the thermal chamber, the chassis was inserted diagonally into the chamber, with the power supply side tilted up. This may mean that the local ambient temperature of the supply was higher than that that measured by the thermocouple, which was located in the chassis center. The internal ambient temperature was allowed to rise with the unit running at the worst case power dissipation (e.g. 180VAC) until the unit shutdown (S/D) and the maximum ambient temperature was then recorded. The device was allowed to cool and restart, and the thermals measured using the nominal supply voltage at both normal room ambient and the elevated temperature at which shut down occurred at low line.
Item Ambient TOPSwitch (U3) Transformer (T1)
180 230 VAC VAC 58 S/D S/D 59 122 73
230 VAC 23 87 52
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
10 Waveforms
10.1 12V Output Turn Off The waveforms shown below were taken with output loads set to 5V/4A, 6.8V/1.5A, and 12V/0.5A, with a fixed 100 ohm resistor on the -10V output. The 5V and 12V outputs were monitored with an oscilloscope. The oscilloscope was triggered on the falling edge of the 5V output. The waveforms show the rise in the lightly loaded 12V output just before the heavily loaded +5V output goes out of regulation after removal of AC power. Use of a heavy foil on the transformer secondaries, along with a small ferrite bead in series with the 12V rectifier, keeps the 12V overshoot within 5%. The ferrite bead also helps to center the 12V output.
Figure 5 - 180 VAC, 5V/4A, 12V/0.5A, 6.8V/1.5A, 10msec/div Upper: 12V, 2V / div Lower: 5V, 1V / div
Figure 6 - 230 VAC, 5V/4A, 12V/0.5A, 6.8V/1.5A, 10msec/div Upper: 12V, 2V / div Lower: 5V, 1V / div
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
Figure 7 - 180VAC, 5V/4A, 12V/0.5A, 6.8V/1.5A, 10msec/div. Upper: 12V Output, 2V / div Lower: 5V Output, 1V / div.
10.2 5V Transient Response Transient response measurements were taken for the 5V output using a 1A-2.5A-1A current step, with the 12V output loaded to 0.5A, and the 6.8v output at 1.5A. The cathode terminal of the TL431 error amplifier was loaded to determine its voltage excursion under these transient conditions. As shown below, the cathode excursion of the TL431 does not approach saturation, under these load conditions.
Figure 11 - 230VAC Input, 5V Load Step of 1A-2.5A1A, 1msec/div. Upper: 5V Load, 1A/div. Middle: TL431 Drain Voltage, 50mV/div. Lower: 5V Output, 50mV/div
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DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
11 Conducted EMI
Tests were performed in open air with resistive load. The supply was mounted inside the chassis. The secondary return was connected to the chassis at the end of the load cable. The primary ground lead (when used) was connected to the chassis using the fast-on terminal provided at the chassis rear panel. The chassis was hard wired to the LISN ground. The margin at the second harmonic will be 2-3dB better using the TDK choke instead of the Panasonic choke.
Figure 30 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits, ground wire connected to chassis.
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Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
Figure 30 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits, ground wire left open.
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Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
12 Revision History
Date April 27, 2004 Author RH Revision 1.0 Description & changes First Release Reviewed VC
Page 22 of 23
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-36
42W, 4 Output Set Top Box Supply
April 27, 2004
For the latest updates, visit our Web site: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION 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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
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