View RD5_1300981.PDF datasheet online --- IC-ON-LINE

Datasheet File OCR Text:

(R) TOPSwitch-II Reference Design Board 85 to 265 VAC Input, 20W (30W Peak) Output
Product Highlights
Low Cost Production Worthy Reference Design * Only 22 components! * Single sided board * Low cost thru-hole components * Fully assembled and tested * Easy to evaluate and modify * Extensive performance data * Up to 80% efficiency * Light weight - no heat sink required for TOPSwitch-II Fully Protected by TOPSwitch-II * Primary safety current limit * Output short circuit protection * Thermal shutdown protects entire power supply Designed for World Wide Operation * Designed for IEC/UL safety requirements * Meets VDE Class B EMI specifications
Figure 1. RD5 Board Overall Physical Dimensions.
1.69 in. (43 mm)
RD5
(R)
3.57 in. (91 mm)
1.06 in. (27 mm)
PI-2058-041698
PARAMETER Input Voltage Range Input Frequency Range Temperature Range Output Voltage (Io = 1.0A) Output Power (continuous) Output Power (peak) Line Regulation (85-265 VAC) Load Regulation (10%-100%) Efficiency Output Ripple Voltage Safety EMI
LIMITS 85 to 265 VAC 47 to 440 Hz 0 to 50C 12 V 5% 25C 20W 50C 15W 30W 1% 1% 78% 60 mV MAX IEC 950 / UL1950 VDE B (VFG243 B) CISPR22
Description
The RD5 reference design board is an example of a very low cost production worthy power supply design using the TOPSwitch family of Three-terminal Off-line PWM Switchers from Power Integrations. It is intended to help TOPSwitch users to develop their products quickly by providing a basic design that can be easily modified to fit a particular application. In most cases, a minor change to the transformer for a different output voltage is all that is needed. Multiple output voltages are obtained just as easily. A constant current or constant power output may be implemented with the addition of a few low cost components. Typical applications include AC-DC adapters for laptops, notebooks and PDAs, battery chargers for cellular telephones, power tools and camcorders, VTR/VCR, video game, appliance and satellite decoder power supplies.
Figure 2. Table of Key Electrical Parameters.
July 1997
RD5
1 7, 8 VR1 P6KE200 5, 6 L2 19 mH BR1 600 V C1 47 F 400 V C6 0.1 F 250 VAC
D
D2 50SQ100 C2 560 F 35 V
L1 3.3 H +12V C3 220 F 35 V RTN
D1 UF4005 2 4
D3 1N4148 C4 0.1 F T1 3 U2 PC817A
R1 39
TOPSwitch-II
CONTROL
R2 150
C
J1 L N
F1 3.15 A
S
U1 TOP224P
C5 47 F
R3 6.8
C7 1 nF 250 VAC Y1
VR2 1N5241B 11 V
PI-2053-041698
Figure 3. Schematic Diagram of the 12V RD5 Power Supply.
BR1
VR1 C1 D2
D1 L2 C6 POWER INTEGRATIONS INC. J1 F1 RD5 S/N Rev. A R3 C5 D3 U2 T1 U1 C4 C7 VR2
C2
L1
R2
R1
J2 +
C3
COMPONENT SIDE SHOWN
PI-2059-062697
Figure 4. Component Legend of the RD5.
General Circuit Description
The RD5 is a low-cost, flyback switching power supply using the TOP224P integrated circuit. The circuit shown in Figure 3 produces a 12 V, 20 W power supply that operates from 85 to 265 VAC input voltage. The 12 V output is directly sensed by optocoupler U2 and Zener diode VR2. The output voltage is determined by the Zener diode (VR2) voltage and the voltage drops across the optocoupler (U2) LED and resistor R1. Other output voltages are also possible by adjusting the transformer turns ratios and value of Zener diode VR2. AC power is rectified and filtered by BR1 and C1 to create the high voltage DC bus applied to the primary winding of T1. The other side of the transformer primary is driven by the integrated high-voltage MOSFET within the TOP224. D1 and VR1 clamp the leading-edge voltage spike caused by transformer leakage inductance to a safe value and reduce ringing. The
34
A 7/97
RD5 Component Listing
Reference BR1 C1 C2 C3 C4 C5 C6 C7* Value 600 V, 2 A 47 F, 400 V 560 F, 35 V 220 F, 35 V 0.1 F, 50 V 47 F, 10 V 0.1 F, 250 VAC, X 1.0 nF, 400 VAC, Y1* Part Number 2KBPC06M 381LX470M400H012 ECA-1VFQ561 ECE-A1VGE221 RPE131R104M50 ECE-A1AG470 F1772-410-2000 DE1110E102M ACT4K-KD (or WKP102MCPE.OK (or PME294RB4100M UF4005 50SQ100 1N4148 622LY-3R3M ELF15N005A 5043CX39R00J 5043CX150R0J 5043CX6R800J TRD5 TOP224P PC817A P6KE200 1N5241B 19372K, 3.15A Manufacturer General Instrument Cornell-Dubilier Panasonic Panasonic Murata Panasonic Roederstein Murata Roederstein) Rifa) General Instrument International Rectifier National Semiconductor Toko Panasonic Philips Philips Philips Custom Power Integrations Sharp General Instrument Motorola Wickman
D1 D2 D3 L1 L2 R1 R2 R3 T1** U1 U2 VR1 VR2 F1
600 V, 1A, UFR 100 V, 5A, Schottky 75 V, Switching 3.3 H, 6.5 A 19 mH, 400 mA 39 , 1/4 W 150 , 1/4 W 6.8 , 1/4 W
200 V Zener TVS 11 V Zener 3.15 A, 250 VAC
Figure 5. Parts List for the RD5 (* Two Series Connected, 2.2 nF, Y2-Capacitors Such as Murata DE7100F222MVA1-KC can replace C7). ** T1 is available from Premier Magnetics (714) 362-4211 as P/N POL-12017, and from Coiltronics (561) 241-7876 as P/N CTX00-13742.
power secondary winding is rectified and filtered by D2, C2, L1, and C3 to create the 12 V output voltage. R2 and VR2 provide a slight pre-load on the 12 V output to improve load regulation at light loads. R2 also provides bias current for Zener VR2 to improve regulation. The bias winding is rectified and filtered by D3 and C4 to create a bias voltage to the TOP224P. L2 and Y1-capacitor C7 attenuate common-mode emission currents caused by high-voltage switching waveforms on the DRAIN side of the primary winding and the primary to secondary capacitance. L2 and C6 attenuate differential-mode emission currents caused by the fundamental and harmonics of the primary current waveform. C5 filters internal MOSFET gate drive charge current spikes on the CONTROL pin, determines the auto-restart frequency, and together with R1 and R3, compensates the control loop. The circuit performance data shown in Figures 6-18 were measured with AC voltage applied to the RD5. Load Regulation (Figure 6) - The amount of change in the DC output voltage for a given change in output current is referred to as load regulation. The 12 V output stays within 1% from
10% to 100% of rated load current. The TOPSwitch on-chip overtemperature protection circuit will safely shut down the power supply under persisting overload conditions. Below minimum load, the 12 V output rises slightly due to the TOPSwitch minimum duty cycle. Line Regulation (Figure 7) - The amount of change in the DC output voltage for a given change in the AC input voltage is called line regulation. The maximum change in output voltage is within 1%. Efficiency (Line Dependent) - Efficiency is the ratio of the output power to the input power. The curves in Figures 8 and 9 show how the efficiency changes with input voltage. Efficiency (Load Dependent) - The curves in Figures 10 and 11 show how the efficiency changes with output power for 115 VAC and 230 VAC inputs. Power Supply Turn On Sequence - The internal switched, highvoltage current source provides the initial bias current for TOPSwitch when power is first applied. The waveforms shown
A 7/97
35
RD5 General Circuit Description (cont.)
in Figure 12 illustrate the relationship between the high-voltage DC bus and the 12 V output voltage. Capacitor C1 charges to the peak of the AC input voltage before TOPSwitch turns on. The delay of 160 ms (typical) is caused by the time required to charge the auto-restart capacitor C5 to 5.8 V. At this point the power supply turns on as shown. Figure 13 shows the output voltage turn on transient as well as a family of curves associated with an additional soft-start capacitor. The soft-start capacitor is placed across VR2 and can range in value from 4.7 uF to 47 uF as shown. Line frequency ripple voltage is shown in Figure 14 for 115 VAC input and 20 W output. Switching frequency ripple voltage is shown in Figure 15 for the same test condition. The power supply transient response to a step load change from 1.25 to 1.67 A (75% to 100%) is shown in Figure 16. Note that the response is quick and well damped. The RD5 is designed to meet worldwide safety and EMI (VDE B) specifications. Measured conduction emissions are shown in Figure 17 for 115 VAC and Figure 18 for 230 VAC. Thermal Considerations The RD5 utilizes the printed circuit copper for TOPSwitch heatsinking. For 20 W output, the heatsink area is approximately 1.25 in2 (8 cm2). The copper area required for heatsinking at 15 W output is outlined on the non-component side of the board, and is approximately 0.56 in2 (3.6 cm2). The RD5 printed circuit board utilizes 2 oz. copper cladding. Printed circuit boards with lighter cladding will require apertures in the solder mask to build-up effective trace thickness.
Transformer Specification
The electrical specifications and construction details for transformer TRD5 are shown in Figures 19 and 20. Transformer TRD5 is supplied with the RD5 reference design board. This design utilizes an EI25 core and a triple insulated wire secondary winding. The use of triple insulated wire allows the transformer to be constructed using a smaller core and bobbin than a conventional magnet wire design due to the elimination of the margins required for safety spacing in a conventional design. If a conventional margin wound transformer is desired, the design of Figures 21-22 can be used. This design (TRD5-1) uses a EEL22 core and bobbin to accommodate the 3 mm margins required to meet international safety standards when using magnet wire rather than triple insulated wire, and has the same pinout and printed circuit foot print as TRD5. The transformer is approximately 50% taller than the triple insulated wire design due to the inclusion of creepage margins required to meet international safety standards.
PI-2062-070297
Output Voltage (% of Nominal)
100
Output Voltage (% of Nominal)
VIN = 115 VAC
100 IL = 1.67 A 50 100 150 200 250
90
0
0.5
1
1.5
2
90
300
Load Current (A)
110 VIN = 230 VAC
Input Voltage (VAC)
110
100
100 IL = 0.33 A 50 100 150 200 250 300
90 0 0.5 1 1.5 2
90
Load Current (A)
Figure 6. Load Regulation
Input Voltage (VAC)
Figure 7. Line Regulation
36
A 7/97
PI-2063-070297
110
110
RD5
PI-2064-070297
Po = 20 W
Po = 4 W
Output Efficiency (%)
60
Output Efficiency (%)
80
80
60
40 20
40 20
0 0 100 200 300
0 0 100 200 300
Input Voltage (VAC)
Figure 8. Efficiency vs. Input Voltage, 20 W Output
100 VIN = 115 VAC 80
Input Voltage (VAC)
Figure 9. Efficiency vs. Input Voltage, 4 W Output
PI-2067-070297
PI-2066-070297
100 VIN = 230 VAC 80
Output Efficiency (%)
Output Efficiency (%)
60
60
40 20
40 20
0 0 5 10 15 20
0 0 5 10 15 20
Output Power (W)
Figure 10. Efficiency vs. Output Power, 115 VAC Input
PI-2068-070297
Output Power (W)
Figure 11. Efficiency vs. Output Power, 230 VAC Input
0 F 4.7 F 10 F 22 F 47 F
PI-2069-070297
DC BUS VOLTAGE
150 100 50 0 15 10 5 0 0 100
10
Output Voltage (V)
8 6 4 2 0
OUTPUT VOLTAGE
200
0
10
PI-2065-070297
100
100
20
Time (ms)
Time (ms)
Figure 12. Turn On Delay
Figure 13. Output Voltage Turn On Transient vs. Soft Start Capacitor
A 7/97
37
RD5
PI-2070-070297 PI-2071-070297
80 60
80 60
Output Voltage (mV)
40 20 0 -20 -40 -60 -80 0 25
Output Voltage (mV)
40 20 0 -20 -40 -60 -80
50
0
25
50
Time (ms)
Time (s)
Figure 14. Line Frequency Ripple, 115 VAC In, 20 W Output Output Current (A) Output Voltage (mV)
Figure 15. Switching Frequency Ripple, 115 VAC In, 20 W Output
100 0 -100 2.0 1.5 1.0 0.5 0 0 10
20
Time (ms) Figure 16. Transient Load Response (75% to 100% of load)
PI-2061-040197
PI-2072-070297
100
VDE B Limit (VFG243A)
100
VDE B Limit (VFG243A)
Amplitude (dBmV)
80 60 40 20 0 0.01 0.1 1 10
Amplitude (dBmV)
80 60 40 20 0 0.01 0.1 1 10
Frequency (MHz)
Figure 17. EMI Characteristics at 115 VAC Input.
Frequency (MHz)
Figure 18. EMI Characteristics at 230 VAC Input.
38
A 7/97
PI-2060-040197
RD5
8 1 67 T #30 AWG 2 3 8T 2x #30 AWG 4
5
7, 8 8T 2x #24 AWG Triple-insulated 5, 6
PIN 1 2 3 4 5, 6 7, 8
FUNCTION HIGH-VOLTAGE DC BUS TOPSwitch DRAIN PRIMARY-SIDE COMMON VBIAS RETURN OUTPUT
1
4
CORE# - PC40 EI25-Z (TDK) GAP FOR AL OF 145 nH/T2 BOBBIN# - BE-25-118CP (TDK)
ELECTRICAL SPECIFICATIONS
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance 60 Hz, 1 minute, from pins 1-4 to pins 5-8 Between pins 1-4 and pins 5-8 Between Pins 1-2 (All other windings open) Between Pins 1-2 (All other windings open) Between Pins 1-2 (Pins 5-8 shorted) 3000 VAC 6.0 mm (min) 650 H, 10% 700 KHz (min) 35 H (max)
NOTE: All inductance measurements should be made at 100 kHz
PI-2054-050798
Figure 19. Electrical specification of transformer TRD5
A 7/97
39
RD5
TAPE
5 6 8 7 3 4 1 2
SECONDARY BIAS PRIMARY
WINDING INSTRUCTIONS
Primary (2 layers) Start at pin 2. Wind 67 turns of #30 AWG heavy nyleze magnet wire in two layers. Finish on Pin 1 1 layer of 10.8 mm wide polyester tape for basic insulation. Start at Pin 4. Wind 8 turns of 2 parallel strands of #30 AWG heavy nyleze magnet wire. Space turns evenly across bobbin to form a single layer. Finish on Pin 3. 1 layer of 10.8 mm wide polyester tape for basic insulation. Start at Pins 7 and 8. Wind 8 bifilar turns of #24 AWG Triple Insulated Wire. Finish on Pins 5 and 6. 3 layers of 10.8 mm wide polyester tape for insulation. Assemble and secure core halves. Impregnate uniformly using varnish.
Basic Insulation Bifilar Bias Winding
Basic Insulation 24 V Double Bifilar Secondary Winding Outer Insulation Final Assembly
* Triple insulated wire sources. P/N: T28A01TXXX-3 Rubudue Wire Company 5150 E. La Palma Avenue Suite 108 Anaheim Hills, CA 92807 (714) 693-5512 (714) 693-5515 FAX P/N: order by description Furukawa Electric America, Inc. 200 Westpark Drive Suite 190 Peachtree City, GA 30269 (770) 487-1234 (770) 487-9910 FAX P/N: order by description The Furukawa Electric Co., Ltd 6-1, Marunouchi 2-chome, Chiyoda-ku, Tokyo 100, Japan 81-3-3286-3226 81-3-3286-3747 FAX
PI-2055-050798
Figure 20. Construction details of transformer TRD5.
40
A 7/97
RD5
8 1 67 T #30 AWG 2 3 8T 2x #30 AWG 4
5
7, 8 8T 2x #24 AWG 5, 6
PIN 1 2 3 4 5, 6 7, 8
FUNCTION HIGH-VOLTAGE DC BUS TOPSwitch DRAIN PRIMARY-SIDE COMMON VBIAS RETURN OUTPUT
1
4
CORE# - PC40 EE22/29/6-Z (TDK) GAP FOR AL OF 145 nH/T2 BOBBIN# - YC 2204 (Ying Chin)
ELECTRICAL SPECIFICATIONS
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance 60 Hz, 1 minute, from pins 1-4 to pins 5-8 Between pins 1-4 and pins 5-8 Between Pins 1-2 (All other windings open) Between Pins 1-2 (All other windings open) Between Pins 1-2 (Pins 5-8 shorted) 3000 VAC 6.0 mm (min) 650 H, 10% 700 KHz (min) 35 H (max)
NOTE: All inductance measurements should be made at 100 kHz
PI-2057-050798
Figure 21. Electrical specification of transformer TRD5-1.
A 7/97
41
RD5
5, 6 7, 8 TAPE 4 3
SECONDARY BIAS TAPE MARGINS PRIMARY
1 2 SLEEVING
WINDING INSTRUCTIONS
Primary Margins Tape margins with 3 mm wide polyester tape. Match height with primary and bias windings. Start at pin 2. Wind one layer (approximately 40 turns) of 30 AWG heavy nyleze magnet wire from bottom (pin side) to top. Use one layer of 12.2 mm wide polyester tape over first primary layer for basic insulation. Continue winding remaining primary turns from top to bottom. Finish on Pin 1. Sleeve start and finish with 24 AWG Teflon sleeving. Use 1 layer of 12.2 mm wide tape for basic insulation. Start at Pin 4. Wind 8 bifilar turns 30 AWG heavy nyleze magnet wire from bottom to top. Spread turns evenly across bobbin. Finish on Pin 3. Sleeve start and finish leads with 24 AWG Teflon sleeving. Use 3 layers of 18.2 mm wide polyester tape for reinforced insulation. Tape margins with 3 mm wide polyester tape. Match height with secondary winding. Start at Pins 7 and 8. Wind 8 bifilar turns of 24 AWG heavy nyleze magnet wire from bottom to top. Spread turns evenly across bobbin. Finish on Pins 5 and 6. Sleeve start and finish leads with 24 AWG Teflon sleeving. Apply 3 layers of 18.2 mm wide polyester tape for outer insulation. Assemble and secure core halves. Impregnate uniformly with varnish.
PI-2056-050798
Primary Windings
Basic Insulation Bias Winding
Reinforced Insulation Secondary Windings
12V Secondary Winding
Outer Insulation Final Assembly
Figure 22. Construction details of transformer TRD5-1.
42
A 7/97
RD5
A 7/97
43
RD5
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein, nor does it convey any license under its patent rights or the rights of others. PI Logo and TOPSwitch are registered trademarks of Power Integrations, Inc. (c)Copyright 1998, Power Integrations, Inc. 477 N. Mathilda Avenue, Sunnyvale, CA 94086 http://www.powerint.com
WORLD HEADQUARTERS NORTH AMERICA - WEST Power Integrations, Inc. 477 N. Mathilda Avenue Sunnyvale, CA 94086 USA Main: +1*408*523*9200 Customer Service: Phone: +1*408*523*9265 Fax: +1*408*523*9365 NORTH AMERICA - EAST & SOUTH AMERICA Power Integrations, Inc. Eastern Area Sales Office 1343 Canton Road, Suite C1 Marietta, GA 30066 USA Phone: +1*770*424*5152 Fax: +1*770*424*6567 EUROPE & AFRICA Power Integrations (Europe) Ltd. Mountbatten House Fair Acres Windsor Berkshire SL4 4LE, United Kingdom Phone: +44*(0)*1753*622*208 Fax: +44*(0)*1753*622*209 TAIWAN Power Integrations International Holdings, Inc. 2F, #508, Chung Hsiao E. Rd., Sec. 5, Taipei 105, Taiwan Phone: +886*2*2727*1221 Fax: +886*2*2727*1223
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
JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222, Japan Phone: +81*(0)*45*471*1021 Fax: +81*(0)*45*471*3717
INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore 560052, India Phone: +91*80*226*6023 Fax: +91*80*228*2191
APPLICATIONS HOTLINE World Wide +1*408*523*9260 APPLICATIONS FAX World Wide +1*408*523*9361
44
A 7/97

▲Up To Search▲

Price & Availability of RD5

	To Download RD5 Datasheet File
If you can't view the Datasheet, Please click here to try to view without PDF Reader .