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Engineering Prototype Report for EP-33 - 45 W LCD Monitor External Power Supply using TOP247Y (TOPSwitch-GX) 90 - 265 VAC Input, 12 V, 3.75 A, 45 W Output LCD Monitor / TV and Generic External Adapter Power Integrations Applications Department EPR-33 28-Mar-03 1.0
Specification Applications Author Document Number Date Revision
Features
* * * * * High efficiency (>79% at end of cord, >83% at supply output) Low zero load power consumption (< 0.25 W at 115 VAC, < 0.3 W at 230 VAC) <1 W input power at 0.5 W load Meets FCC part 15B and CISPR22 conducted EMI with margin even with output RTN connected to protective earth ground Design tailored to meet typical LCD monitor external supply specifications
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, Inc. 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-33 - 45 W External Adapter Supply Table Of Contents
28-Mar-2003
Introduction ........................................................................................................................... 4 Power Supply Specification................................................................................................... 5 Schematic ............................................................................................................................. 6 Circuit Description ................................................................................................................. 7 4.1 Input EMI Filtering ......................................................................................................... 7 4.2 TOPSwitch-GX Primary................................................................................................. 7 4.3 Output Rectification ....................................................................................................... 7 4.4 Output Feedback........................................................................................................... 7 5 PCB Layout........................................................................................................................... 9 6 Bill Of Materials................................................................................................................... 10 7 Transformer Specification ................................................................................................... 11 7.1 Electrical Specifications............................................................................................... 11 7.2 Materials...................................................................................................................... 11 7.3 Transformer Build Diagram.......................................................................................... 12 7.4 Transformer Construction............................................................................................ 12 7.5 Transformer Sources................................................................................................... 12 8 Transformer Spreadsheet ................................................................................................... 13 9 Performance Data............................................................................................................... 15 9.1 Efficiency..................................................................................................................... 15 9.2 No-load Input Power.................................................................................................... 16 9.3 Input Power at 0.5 W Load .......................................................................................... 16 9.4 Regulation ................................................................................................................... 17 9.4.1 Load .................................................................................................................... 17 9.4.2 Line ..................................................................................................................... 17 10 Thermal Performance...................................................................................................... 18 11 Waveforms...................................................................................................................... 19 11.1 Drain Voltage and Current, Normal Operation ............................................................. 19 11.2 Output Voltage Start-up Profile.................................................................................... 20 11.3 Drain Voltage and Current Start-up Profile .................................................................. 21 11.4 Load Transient Response (75% to 100% Load Step) .................................................. 22 11.5 Output Ripple Measurements ...................................................................................... 23 11.5.1 Ripple Measurement Technique .......................................................................... 23 11.5.2 Measurement Results.......................................................................................... 24 12 Control Loop Measurements ........................................................................................... 25 12.1 115 VAC Maximum Load............................................................................................. 25 12.2 230 VAC Maximum Load............................................................................................. 26 13 Conducted EMI ............................................................................................................... 27 14 AC Surge and 100 kHz Ring Wave Immunity .................................................................. 28 14.1 Common Mode Surge, 1.2/50 sec................................................................................. 28 14.2 Differential Mode Surge, 1.2/50 sec........................................................................... 28 14.3 Common Mode, 100 kHz Ring Wave........................................................................... 29 14.4 Differential Mode, 100 kHz Ring Wave ........................................................................ 29 15 Appendix ......................................................................................................................... 30 15.1 Input Cable Bill of Materials ......................................................................................... 30 15.2 Input Cable Assembly.................................................................................................. 30 15.3 Heat Sink Assembly .................................................................................................... 31 16 Revision History .............................................................................................................. 32
1 2 3 4
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Page 2 of 32
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EPR-33 - 45 W External Adapter Supply
Important Note: Although the EP-33 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.
Page 3 of 32
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
1
Introduction
This document is an engineering report describing a 12 V, 45 W power supply, with intended application such as W LCD monitor adapters. This document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit board layout, and performance data.
Figure 1 - EP-33 Populated Circuit Board.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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28-Mar-2003
EPR-33 - 45 W External Adapter Supply
2
Power Supply Specification
Description Symbol VIN fLINE Min 90 47 Typ Max 265 64 0.3 12.6 120 Units VAC Hz W V mV A W W % Comment
3 Wire Measured at 230 VAC, 60 Hz 5% 20 MHz Bandwidth
Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Safety Surge Surge Ambient Temperature
50/60
VOUT1 VRIPPLE1 IOUT1 POUT POUT_PEAK
11.5 0.0 45 45 83
12.00 3.75
Measured at POUT (45 W), 25 C
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II 1.2/50 s surge, IEC 1000-4-5, 12 series impedance, differential and common mode 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level
3 3 TAMB 0 50
kV kV C
Page 5 of 32
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
3
Schematic
Figure 2 - EP-33 Schematic.
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EPR-33 - 45 W External Adapter Supply
4
Circuit Description
The schematic in Figure 2 shows an off-line flyback converter using the TOP247Y. The circuit is designed for 90 VAC to 265 VAC input and 12 V, 3.75 A output. 4.1 Input EMI Filtering Capacitor CX1 and the L1 leakage inductance filter differential-mode conducted EMI. Inductor L1 and CY1 filter common-mode conducted EMI. Inductor L4 damps line-cord resonance. 4.2 TOPSwitch-GX Primary Rectifier bridge BR1 and C1 provide a high voltage DC BUS for the primary circuitry. C2 bypasses the high voltage DC rail. Resistor R11 provides damping that reduces midfrequency conducted EMI. The DC rail is applied to the primary winding of T1. The other side of the transformer primary is driven by the integrated MOSFET in U1. Diode D1 and VR1 clamp leakage spikes generated when the MOSFET in U1 switches off. Capacitor C3 reduces the operating temperature of VR1 by bypassing the leading edge of the primary leakage spike away from VR1. Resistor R2 provides damping to reduce drain ringing. Resistor R1 sets the low-line turn-on threshold to approximately 69 VAC, and also sets the overvoltage shutdown level to approximately 320 VAC. R3 sets the U1 current limit to approximately 55% of its nominal value. This limits the output power delivered during fault conditions. C4 bypasses the U1 CONTROL pin. C5 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. R4 adds a zero to stabilize the power supply control loop. Diode D2 and C6 provide rectified and filtered bias power for U2 and U1. 4.3 Output Rectification The output of T1 is rectified and filtered by D3, C7, and C8. Inductor L2, C9, and C10 provide additional high frequency filtering. Resistor R12 and C13 provide snubbing for D3. Choosing the proper snubber values is important for low zero-load power consumption and for high frequency EMI suppression. The snubber components were chosen so that the turn-on voltage spike at the D3 anode is slightly under-damped. Increasing C13 and reducing R12 will improve damping and high frequency EMI, at the cost of higher zero-load power consumption. 4.4 Output Feedback Resistors R8 and R9 divide down the supply output voltage and apply it to the reference pin of error amplifier U3. Shunt regulator U3 drives optocoupler U2 through resistor R6 to provide feedback information to the U1 CONTROL pin. The optocoupler output also provides power to U1 during normal operating conditions. Diode D4 and C11 apply drive to the optocoupler during supply startup to eliminate output voltage overshoot. Diode D4 isolates C11 from the supply feedback loop after startup. Resistor R5 discharges C11 when the supply is off.
Page 7 of 32
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
Components C5, C12, R4, R6, and R7 all play a role in compensating the power supply control loop. Capacitor C5 rolls off the gain of U1 at relatively low frequency. Resistor R4 provides a zero to cancel the phase shift of C5. Resistor R6 sets the gain of the direct signal path from the supply output through U2 and U3. Components C12 and R7 roll off the gain of U3.
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28-Mar-2003
EPR-33 - 45 W External Adapter Supply
5
PCB Layout
Figure 3 - EP-33 Printed Circuit Board Layout (dimensions 0.001").
Page 9 of 32
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EPR-33 - 45 W External Adapter Supply
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6
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Bill Of Materials
Qty 1 1 1 1 3 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Reference CX1 C1 C2 C3 C4, 10, 12 C5 C6 CY1 C7, 8 C9 C11 C13 BR1 D1 D2, 4 D3 F1 L1 L2 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 T1 Description 0.33 F, 250 V, X2 100 F, 400 V 20 nF, 1 kV disc 4.7 nF, 1 kV disc 100 nF, 50 V 47 F, 16 V, 105 C 1 F, 50 V, 105 C 2.2 nF, Y1 680 F, 35 V, low ESR 100 F, 35 V, 105 C 10 F, 50 V, 105 C 470 pF, 100 V, X7R Bridge, 4 A, 600 V 1 A, 600 V, 75 ns UF4005 Diode, Signal 20 A, 100 V, Schottky Fuse, 250 VAC, 3.15 A 9.5 mH, 1.2 A 3.3 H, 5.5 A 2 M, 5%, 1/2 W 68 , 5%, 1/2 W 16.5 k, 1%, 1/8 W 6.8 , 5%, 1/8 W 15 k, 5%, 1/8 W 1 k, 5%, 1/8 W 3.3 k, 5%, 1/8 W 10 k, 1%, 1/8 W 38.3 k, 1%, 1/8 W 8.2 M, 5%, 1/2 W 2.2 , 5%, 1/4 W 33 , 1/4 W, 5% Transformer, EE28 P/N Manufacturer ECQ-U2R334ML Panasonic PAG400VB101M16X30 United Chemicon 5GAS20 Vishay 5GAD47 Vishay C320C104K1R5CA Kemet ECA-1CHG470 Panasonic ECA-1HHG010 Panasonic 440LD22 Cera-Mite KZE35VB681M12.5X20 United Chemicon ECA-1VHG101 Panasonic ECA-1HHG100 Panasonic C315C471K1R5CA Kemet RS405M Rectron General Semiconductor 1N4148 MBR20100 General Semiconductor 372-1315 Wickman ELF-18N012A Panasonic 6000-3R3M J. W. Miller Any Any Any Any Any Any Any Any Any Any Any Any 545 90 009 00 Vogt SIL6019 Hical EXL-529 Rev. B Excel Electric Power Integrations ISP817C Isocom
EP-33 Rev. 10, 01/16/03 Bill Of Materials
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
1 1 1 1 1 1 1 2 2 2 1 1 2 A/R 1
U1 U2 U3 VR1 RT1 J1 J2 HS1, HS2 U1, D3 U1, D3 D3 D3 U1, D3 JP1-3
TOP247Y Optocoupler Graded CTR Shunt Regulator, TO-92 LM431ACZ National Semiconductor TVS, 200 V P6KE200 On Semiconductor Thermistor, 5 , 3 A SCK-053 Thinking Electronic Assembly, AC Receptacle see Appendix Assembly, Output Cable, 6', 2 x 18 gauge, 2.5 mm female barrel connector, 14.3 mm x 28.6 mm molded ferrite filter Assembly, EP-33 Heat Sink see Appendix Screw, 4-40 Phil Flat Undercut Zinc, 5/16" Nut, 4-40 Kep Zinc Insulator, Silicone 188858F00000 Aavid/Thermalloy TO-220 4-40 Shoulder Washer 3049 Keystone Electronics 0.031" Shank Washer, 4-40 Zinc Bus Wire, 22 AWG EP-33 PCB, Rev. A
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 10 of 32
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EPR-33 - 45 W External Adapter Supply
7
Transformer Specification
1
WDG #1 32T #25 AWG
3
9,10
WDG #3 4T 6 X 25 AWG Triple insulated
4
7,8
WDG #2 3T 3 X #28 AWG
5
Figure 4 - EP-33 Triple Insulated Transformer.
7.1
Electrical Specifications
60 Hz, 1 min, from Pins 1-5 to Pins 6-10 Between Pins 1-5 and Pins 6-10 Pins 1-3, all other windings open, measured at 100 kHz Pins 1-3, all other windings open Pins 1-3, with Pins 6-10 shorted, measured at 100 kHz 3000 VAC 6 mm (Min.) 521 H, 10% 1.2 MHz (Min.) 12 H (Max.)
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance
7.2
Materials
Item [1] [2] [3] [4] [5] [6] [7] Description Core: Nippon Ceramic FEE28/21/11, NC-2H material or equivalent. Gap for 2 AL of 509 nH/T Bobbin: 10 Pin EI28, Vertical Mount, Yih Hwa YW-490 or equivalent Magnet Wire: #25 AWG Double Coated Magnet Wire: #28 AWG Double Coated Triple Insulated Wire: #25 AWG Tape, 3M #1298 or equiv. 8.6 mm wide Varnish
Page 11 of 32
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
7.3
Transformer Build Diagram
Pins Side
7,8 9,10 5 4 1 3
Secondary Bias Primary
Figure 5 - EP-33 Transformer Build Diagram.
7.4
Transformer Construction
Start at Pin 3. Wind 16 turns of item [3] in one layer. Apply one layer of item [6] over completed winding layer. Wind remaining 16 turns, finish on Pin 1. Apply one layer of item [6] for basic insulation. Starting at Pin 4, wind 3 trifilar turns of item [4]. Spread turns evenly across bobbin. Finish at Pin 5. Use two layers of item [6] for basic insulation. Start at Pins 9 and 10. Wind 4 hexafilar turns of item [5]. Spread turns evenly across bobbin. Finish on Pins 7 and 8. Wrap windings with 3 layers of tape (item [6]). Assemble and secure core halves. Varnish impregnate (item [7]).
1/2 Primary Basic Insulation 1/2 Primary Basic Insulation Trifilar Bias winding Basic Insulation Hexafilar Secondary Winding Outer Wrap Final Assembly
7.5 Transformer Sources For information on the vendors used to source the transformers used on this board, please visit the Power Integrations' Web site at the URL below and select "Engineering Prototype Boards". http://www.powerint.com/componentsuppliers.htm
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EPR-33 - 45 W External Adapter Supply
8
Transformer Spreadsheet
Power Supply Input VACMIN VACMAX FL TC Z N % Volts Volts Hertz msonds 89 265 50 2.11 0.49 80.0 Min Input AC Voltage Max Input AC Voltage AC Main Frequency Bridge Rectifier Conduction Time Estimate Loss Allocation Factor Efficiency Estimate
Power Supply Outputs VOx IOx VB IB Volts Amps Volts Amps 12.00 0.006 12.00 Output Voltage 3.750 Output Current Bias Voltage Bias Current
Device Variables Device PO VDRAIN VDS FS KRPKDP KI ILIMITEXT ILIMITMIN ILIMITMAX IP IRMS DMAX Amps Amps Amps Amps Amps Watts Volts Volts Hertz TOP247Y/ F 45.07 605 3.9 132000 0.40 0.55 1.84 3.35 3.85 1.52 0.91 0.56 Device Name Total Output Power Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Device On-State Drain to Source Voltage Device Switching Frequency Ripple to Peak Current Ratio External Current Limit Ratio Device Current Limit External Minimum Device Current Limit Minimum Device Current Limit Maximum Peak Primary Current Primary RMS Current Maximum Duty Cycle
Power Supply Components Selection CIN VMIN VMAX VCLO PZ VDB PIVB uFarads Volts Volts Volts Watts Volts Volts 100.0 83 375 150 2.1 0.7 60 Input Filter Capacitor Minimum DC Input Voltage Maximum DC Input Voltage Clamp Zener Voltage Estimated Primary Zener Clamp Loss Bias Winding Diode Forward Voltage Drop Bias Rectifier Maximum Peak Inverse Voltage
Page 13 of 32
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
Power Supply Output Parameters VDx PIVSx ISPx ISRMSx IRIPPLEx Volts Volts Amps Amps Amps 0.5 Output Winding Diode Forward Voltage Drop 59 Output Rectifier Maximum Peak Inverse Voltage 11.95 Peak Secondary Current 6.43 Secondary RMS Current 5.22 Output Capacitor RMS Ripple Current
Transformer Construction Parameters Core/Bobbin Core Manuf. Bobbin Manuf LP NP NB AWG AWG uHenries EI28 Generic Generic 521 32 4.06 24 Core and Bobbin Type Core Manufacturing Bobbin Manufacturing Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns Primary Wire Gauge (Rounded to next smaller standard AWG value) Warning! Primary wire gauge is less than recommended minimum (26 AWG) and may overheat Tip: Consider a parallel winding technique (bifilar, trifilar), increase size of transformer (larger BW) Primary Winding Current Capacity Reflected Output Voltage Bobbin Physical Winding Width Safety Margin Width Number of Primary Layers Core Effective Cross Section Area Gapped Core Effective Inductance Maximum Operating Flux Density Peak Flux Density AC Flux Density for Core Curves Gap Length Estimated Transformer Primary Leakage Inductance Estimated Secondary Trace Inductance
CMA VOR BW M L AE ALG BM BP BAC LG LL LSEC
Cmils/A Volts mm mm cm^2 nH/T^2 Gauss Gauss Gauss mm uHenries nHenries
444 100.00 9.60 0.0 2.0 0.86 509 2871 4013 574 0.19 3.9 10
Secondary Parameters NSx Rounded Down NSx Rounded Volts Down Vox Rounded Up NSx Rounded Up Vox AWGSx Range Volts AWG 4.00 Secondary Number of Turns Rounded to Integer Secondary Number of Turns Auxiliary Output Voltage for Rounded to Integer NSx Rounded to Next Integer Secondary Number of Turns Auxiliary Output Voltage for Rounded to Next Integer NSx 15 - Secondary Wire Gauge Range 19 Comment: Primary wire gauge is less than recommended minimum (26 AWG) and may overheat Tip: Consider a parallel winding technique (bifilar, trifilar), increase size of transformer (larger BW) or reduce margin (M).
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Page 14 of 32
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EPR-33 - 45 W External Adapter Supply
9
9.1
Performance Data
Efficiency
All measurements performed at room temperature, 60 Hz input frequency.
EP-33 Efficiency vs. Input Voltage, Full Load
88% 87% 86%
Efficiency (%)
85% 84% 83% 82% 81% 80% 79% 80 100 120 140 160 180 200 220 240 260 280 Efficiency at Supply Output Efficiency at Cable End
Input Voltage (VAC)
Figure 6 - Efficiency vs. Input Voltage, Full Load, Room Temperature, 60 Hz.
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
9.2
No-load Input Power
EP-33 No-Load Input Power vs. Line Voltage
0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 80 100 120 140 160 180 200 220 240 260 280
Input Power (W)
Input Voltage (VAC) Figure 7 - No-Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
9.3
Input Power at 0.5 W Load
EP-33 Input Power vs. Line Voltage, 0.5 W Load
1
0.95
Input Power (W)
0.9
0.85
0.8
0.75 80 100 120 140 160 180 200 220 240 260 280
Input Voltage (VAC) Figure 8 - Input Power vs. Line Voltage, 0.5 W Load, Room Temperature.
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Page 16 of 32
28-Mar-2003 9.4 Regulation
EPR-33 - 45 W External Adapter Supply
9.4.1 Load EP-33 Load Regulation
105%
Regulation (% of Nominal)
103%
90 VAC, Output 90 VAC, End of Cable
101%
115 VAC, Output 115 VAC, End of Cable
99%
230 VAC, Output 230 VAC, End of Cable
97%
265 VAC, End of Cable
95% 0 1 2 3 4
Output Load (A)
Figure 9 - Load Regulation, Room Temperature.
9.4.2 Line EP-33 Line Regulation, Full Load
105%
Regulation (% of Nominal)
104% 103% 102% 101% 100% 99% 98% 97% 96% 95% 80 100 120 140 160 180 200 220 240 260 280 Supply Output End of Cable
Input Voltage (VAC)
Figure 10 - Line Regulation, Maximum Load, Room Temperature.
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
10
Thermal Performance
Temperature (C) Item Thermistor (RT1) Balun (L1) Bridge (BR1)
TOPSwitch-GX (U1)
90 VAC
73 48 72 60 93 64 83 25
115 VAC
64 42 61 53 84 60 80 25
230 VAC
44 32 49 52 70 56 73 26
90 VAC
93 78 97 91 115 90 107 50
115 VAC
80 67 85 84 103 89 102 50
230 VAC
65 58 71 78 92 80 98 49
Clamp Zener (VR1) Transformer (T1) Rectifier (D3) Ambient
Figure 11 - Infrared Thermograph of EP-33, 90 VAC Input, Full Load, 25 C Ambient.
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EPR-33 - 45 W External Adapter Supply
11
11.1
Waveforms
Drain Voltage and Current, Normal Operation
Figure 12 - 90 VAC - Upper: IDRAIN, 0.5 A/div. Lower: VDRAIN, 100 V, 2 s/div.
Figure 13 - 265 VAC, Full Load Upper: IDRAIN, 0.5 A/div. Lower: VDRAIN, 200 V, 2 s/div.
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
11.2
Output Voltage Start-up Profile
Figure 14 - Start Up Profile at Supply Output, Full Load, 115 VAC, 2 V, 10 ms/div.
Figure 15 - Start Up Profile at Supply Output Zero Load, 115 VAC. 2 V, 10 ms/div.
Figure 16 - Start-up Profile at Supply Output Full Load, 230 VAC. 2 V, 10 ms/div.
Figure 17 - Start Up Profile at Supply Output Zero Load, 230 VAC, 2 V, 10 ms/div.
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EPR-33 - 45 W External Adapter Supply
11.3
Drain Voltage and Current Start-up Profile
Figure 18 - 90 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A/div. Lower: VDRAIN, 100 V , 10 ms/div.
Figure 19 - 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A/div. Lower: VDRAIN, 200 V, 10 ms/div.
Page 21 of 32
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EPR-33 - 45 W External Adapter Supply
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11.4 Load Transient Response (75% to 100% Load Step) In the figures shown below, signal averaging was used to better enable viewing the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response.
Figure 20 - 115 VAC Transient Response. 75%-100%-75% Load Step. Top: Load Current, 2 A/div. Bottom: Voltage at Supply Output 100 mV, 500 s/div.
Figure 21 - 230 VAC Transient Response. 75%-100%-75% Load Step. Top: Load Current, 2 A/div. Bottom: Voltage at Supply Output 100 mV, 1 ms/div.
Figure 22 - 115 VAC Transient Response. 75%-100%-75% Load Step at End of Cable. Top: Load Current, 2 A/div. Bottom: Voltage at End of Cable 100 mV, 500 s/div.
Figure 23 - 230 VAC Transient Response 75%-100%-75% Load Step at End of Cable. Top: Load Current, 2 A/div. Bottom: Voltage at End of Cable 100 mV, 1 ms/div.
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EPR-33 - 45 W External Adapter Supply
11.5
Output Ripple Measurements
11.5.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 24 and Figure 25. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 24 - Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).
Figure 25 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with wires for probe ground for ripple measurement and two parallel decoupling capacitors added).
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
11.5.2 Measurement Results
Figure 26 - Ripple, 90 VAC, Full Load at End of Cable. 2 ms, 50 mV/div.
Figure 27 - Ripple, 115 VAC, Full Load at End of Cable. 2 ms, 50 mV/div.
Figure 28 - Ripple, 230 VAC, Full Load at End of Cable. 2 ms, 50 mV/div.
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EPR-33 - 45 W External Adapter Supply
12
12.1
Control Loop Measurements
115 VAC Maximum Load
Figure 29 - Gain-Phase Plot, 115 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div., Phase = 50/div. Crossover Frequency - 1.43 kHz, Phase Margin - 62.6
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EPR-33 - 45 W External Adapter Supply
28-Mar-2003
12.2
230 VAC Maximum Load
Figure 30 - Gain-Phase Plot, 230 VAC, Maximum Steady State Load. Vertical Scale: Gain = 10 dB/div., Phase = 50/div. Crossover Frequency - 1.86 kHz, Phase Margin - 64.7
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EPR-33 - 45 W External Adapter Supply
13
Conducted EMI
Figure 31 - Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits.
Figure 32 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits.
Conducted EMI was measured with output return connected to ground of LISN.
Page 27 of 32
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EPR-33 - 45 W External Adapter Supply
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14
AC Surge and 100 kHz Ring Wave Immunity
Four series of line transient tests were performed on the EP-33 to determine the level of immunity attainable for the basic board. Testing was performed using a Keytek EMC-Pro surge generator. The input voltage for the supply under test was 230 VAC, and the supply was resistively loaded to the maximum continuous output power. The UUT secondary return was hard wired to the surge generator earth connection to simulate use in an actual system. An LED was used to monitor the presence of output voltage and to detect output interruptions. The test for each series was terminated upon non-destructive interruption of output voltage, arcing, or non-recoverable interruption of output voltage. A test failure was defined as a non-recoverable interruption of output voltage requiring supply repair or recycling of input AC voltage. 14.1 Common Mode Surge, 1.2/50 sec
Surge Voltage 1 kV 1 kV 1 kV 2 kV 2 kV 2 kV 2.5 kV 2.5 kV 2.5 kV
3 kV 3 kV 3 kV
Phase Angle ()
0 90 270 0 90 270 0 90 270 0 90 270
Generator Impedance 12 12 12 12 12 12 12 12 12
12 12 12
Number of Strikes 10 10 10 10 10 10 10 10 10
10 10 10
Test Result
Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass (1 interruption/10 strikes, supply recovered) Pass (1 interruption/10 strikes, supply recovered) Pass
14.2 Differential Mode Surge, 1.2/50 sec
Surge Voltage 1 kV 1 kV 1 kV 2 kV 2 kV 2 kV 3 kV 3 kV 3 kV 4 kV 4 kV 4 kV Phase Angle ()
0 90 270 0 90 270 0 90 270 0 90 270
Generator Impedance 12 12 12 12 12 12 12 12 12 12 12 12
Number of Strikes 10 10 10 10 10 10 10 10 10 10 10 10
Test Result
Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 28 of 32
28-Mar-2003 14.3 Common Mode, 100 kHz Ring Wave
Surge Voltage (kV) 1 kV 1 kV 1 kV 2 kV 2 kV 2 kV 3 kV 3 kV 3 kV
4 kV
EPR-33 - 45 W External Adapter Supply
Phase Angle ()
0 90 270 0 90 270 0 90 270 0
Short Circuit Current
500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A
Number of Strikes
10 10 10 10 10 10 10 10 10 1
Test Result
Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass (Supply arcing, no power interruption)
14.4
Differential Mode, 100 kHz Ring Wave
Surge Voltage 1 kV 1 kV 1 kV 2 kV 2 kV 2 kV 3 kV 3 kV 3 kV 4 kV 4 kV 4 kV Phase Angle ()
0 90 270 0 90 270 0 90 270 0 90 270
Short Circuit Current 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A 500 A
Number of Strikes 10 10 10 10 10 10 10 10 10 10 10 10
Test Result
Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass
Page 29 of 32
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-33 - 45 W External Adapter Supply
28-Mar-2003
15
Appendix
[2] [1] [5], [8]
L E N
[6] (3 places)
[4] [3] [7] (3 places)
15.1
Input Cable Bill of Materials
EP-33 Input Assy Rev.2, 11/18/02 Bill Of Materials Item 1 2 3 4 5 6 7 8 Qty 1 A/R A/R A/R 1 3 A/R A/R Reference J1 Description P/N Input Receptacle 701W-X2/02 Wire, 18 AWG, UL 1007, Black, 0.08" dia Wire, 18 AWG, UL 1007, White, 0.08" dia. Wire, 18 AWG, UL 1007, Grn/Yel, 0.08" dia Ferrite Bead 2643006302 Board-in Terminal 02-07-2102 Heat Shrink FIT221V-3/16 3/16", UL VW-1 Heat Shrink, FIT221V-1/2 Alpha Manufacturer Qualtek
L5
Fair-Rite Molex Alpha
15.2 1) 2) 3) 4) 5) 6) 7)
Input Cable Assembly
Cut 1 each 2" length items [2] and [3]. Strip 0.25" each end Crimp 1 piece item [6] on one end of each wire. Cut one 12 " piece item [4] Center 1 piece item [5] on item [4] cut length, wind 3 turns item [4] on item [5]. Trim one end item [4]. [5] assembly to 1.5", other end to 4". Strip both ends 0.25". Crimp one piece item [6] on 4" end of item [4], [5] assembly. Cut 3/4" length item [8], slide over item [4], [5] assembly so that it is centered on item [5], shrink in place. 8) Solder remaining stripped ends of wires to receptacle [1] as shown, insulate each connection using 0.5" item [7].
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 30 of 32
28-Mar-2003
EPR-33 - 45 W External Adapter Supply
15.3
Heat Sink Assembly
Page 31 of 32
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-33 - 45 W External Adapter Supply
28-Mar-2003
16
Revision History
Date 18-Nov-2002 22-Nov-2002 06-Dec-02 28-Mar-03 Author RH RH RH RH Revision 0.1 0.2 0.3 1.0 Description & changes First draft Second Draft Third Draft First Release
For the latest updates, visit our Web site: www.powerint.com PATENT INFORMATION 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. 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, Inc. PI Expert and DPA-Switch are trademarks of Power Integrations, Inc. (c) Copyright 2003, Power Integrations, Inc.
WORLD HEADQUARTERS NORTH AMERICA - WEST Power Integrations, Inc. 5245 Hellyer Avenue San Jose, CA 95138 USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: usasales@powerint.com CHINA Power Integrations International Holdings, Inc. Rm# 1705, Block A Bao Hua Bldg. 1016 Hua Qiang Bei Lu Shenzhen Guangdong, 518031 Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660
EUROPE & AFRICA Power Integrations (Europe) Ltd. Centennial Court Easthampstead Road Bracknell Berkshire RG12 1YQ, United Kingdom Phone: +44-1344-462-300 Fax: +44-1344-311-732 e-mail: eurosales@powerint.com KOREA Power Integrations International Holdings, Inc. Rm# 402, Handuk Building, 649-4 Yeoksam-Dong, Kangnam-Gu, Seoul, Korea Phone: +82-2-568-7520 Fax: +82-2-568-7474 e-mail: koreasales@powerint.com
SINGAPORE Power Integrations, Singapore 51 Goldhill Plaza #16-05 Republic of Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com
TAIWAN Power Integrations International Holdings, Inc. 17F-3, No. 510 Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore, India 560052 Phone: +91-80-226-6023 Fax: +91-80-228-9727 e-mail: indiasales@powerint.com
JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com
APPLICATIONS FAX World Wide +1-408-414-9760
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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