DER-100 POWERINT | Alldatasheet
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Power Integrations, Inc. 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Design Example Report Title 24 W Primary–side Regulated Flyback Power Supply using TOP245Y Specification Input: 90 – 265 VAC Output: 8V / 3A Application LED Lighting Author Power Integrations Applications Department Document Number DER-100 Date December 7, 2005 Revision 2.0 Summary This report details the design of a primary-side regulated isolated Flyback converter.
- Provides 8 V @ 3 A
- Typical Efficiency 80 %.
- Primary-side regulation
- Low parts count 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.
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 2 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Table Of Contents 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 spec ification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 3 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
1 Introduction
This document is an engineering report giving performance characteristics of a 24 W Flyback converter – 8 V @ 3 A. This design uses TOPSwitch-GX – an integrated IC comprising a high voltage MOSFET, and PWM controller. This document contains power supply specification, schematic, bill-of-materials, transformer documentation, printed circuit layout, and performance data. A photo of the power supply prototype is shown in Figure 1. Figure 1 – Power Supply Prototype – Top View
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 4 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
2 Power Supply Specification
Description Symbol Min Typ Max Units Comment Input Voltage VIN 90 265 Vac Outputs Output Voltage VOUT 8 V Output Ripple Voltage VRIPPLE 200 mV 20 MHz Bandwidth Output Current IOUT 3 A Continuous Continuous Output Power POUT 24 W Conducted EMI Margin 10 dB EN550022 B, FCC B Efficiency η 80 % At full load Ambient Temperature TAMB 0 50 oC Free convection, Sea level Table 1 – Power Supply Specification
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 5 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
3 Schematic
275 VAC
N +8V @ 3A 100 1 nF 1 kV L C13 47 uF 10 V RTN t RT1 10 ohms 4 - + DF06S 600 V 8.2 ohm 2.2 nF 11k 1N4007GP C S D L F CONTROL X TOP245Y 3.15A 10 mH C12 100 nF 50 V VR1 P6KE200A 90 - 265 VAC 50/60Hz 43CTQ100S ES1D C14 1.0 uF 50 V VR2 ZMM5243B-7 13 V 1200uF 35 V 1200uF 35 V 10T1 EI25 160 Figure 2 – 24 W, Power Supply Schematic
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 6 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
4 Bill Of Materials
Item QTY Part Reference Description Mfg Mfg Part Number 1 1 C1 2.2nF, Ceramic, Y1 Vishay 440LD22 2 1 C3 100uF, 400 V, Electrolytic, High Ripple Panasonic 3 1 C5 1nF, 1 kV, Disc Ceramic NIC Components Corp NCD102K1KVY5F 4 2 C7 C8 100uF, 35 V, Electrolytic, Low ESR Panasonic 5 1 C10 100nF, 275 VAC, Film, X2 Panasonic ECQ-U2A104ML 6 1 C12 100nF, 50 V, Ceramic, X7R, 0805 Panasonic ECU-V1H221KBN 7 1 C13 47uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) United Chemi-Con KME10VB22RM5X11LL 8 1 C14 1.0uF, 50 V, Ceramic, Z5U Panasonic ECU-S1H105MEB 9 1 D1 600 V, 1 A, Bridge Rectifier, SMD, DFS Vishay 10 1 D4 1000 V, 1 A, Rectifier, DO-41 Vishay 1N4007GP 11 1 D5 100 V, 43 A, Dual Schottky, (D2-PAK) International Rectifier 43CTQ100S 12 1 D6 100 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC Vishay ES1D 13 1 F1 3.15 A, 250V, Slow, TR5 Wickman 3,721,500,041 14 1 R2 100 R, 1%, 1/4 W, Metal Film Yageo MFR-25FBF-102R 15 1 R3 2 M, 5%, 1/4 W, Metal Film, 1206 Panasonic ERJ-8GEYJ205V 16 1 R6 8.2 R, 5%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6GEYJ8R2V 17 1 R7 15 k, 1%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6ENF1502V 18 1 R8 160 R, 5%, 1/4 W, Metal Film, 1206 Panasonic ERJ-8ENF1620V 19 1 RT1 NTC Thermistor, 5 Ohms, 2.8 A Thermometrics CL160 20 1 T1 Bobbin, EI25, Horizontal, 10 pins Epcos 21 1 T2 10 mH, 1A, Common Mode Choke Tokin SC-01-E100G 22 1 U1 TOPSwitch-GX, TOP245Y, TO-263-7C Power Integrations TOP245Y 23 1 VR1 200 V, 5 W, 5%, DO204AC (DO-15) Vishay P6KE200A 24 1 VR2 13 V, 5%, 500 mW, DO-213AA (MELF) Diodes Inc ZMM5243B-7 Table 2 – Bill of Materials
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 7 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
5 Transformer Specification
Core Material NC-2H or Equivalent Estimated Gap length, mm 0.362 Gapped Effective Inductance, nH/t^2 133 Primary Inductance, uH 686 Bobbin Information (Manual Input) Bobbin Reference Generic, 5 pri. + 5 sec. Bobbin Orientation Vertical
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 8 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Number of Primary pins 5 Number of Secondary pins 5 Margin on Bottom, mm 0.0 Margin on Top, mm 0.0 Primary Winding (Manual Input) Parameter Section 1 Number of Turns 72 Wire Size, AWG 28 Filar 1 Layers 2.69 Start Pin(s) 3 Termination Pin(s) 1 BIAS Winding Parameter Value Number of Turns 10 Wire Size, AWG 28 Filar 2 Layers 0.75 Start Pin(s) 5 Termination Pin(s) 4 Shield Information Parameter Primary Cancellation Number of Turns 7 13 Wire Size, AWG 27 28 Filar 2 2 Layers 0.58 0.97 Start Pin(s) NC 1,2 Termination Pin(s) 1,2 NC Secondary Winding (Manual Input) Parameter Output 1 (main) Spec Voltage, V 8.00 Spec Current, A 3.00 Actual Voltage, V 8.00 Number of Turns 8 Wire Size, AWG 27 Filar 2 Layers 0.90 Start Pin(s) 10 Termination Pin(s) 6 Winding Instruction Cancellation Shield Winding Start on pin(s) 1,2 and wind 13 turns (x 2 filar) of item [6]. in exactly 1 layer. Leave this end of
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 9 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com the bobbin. Add 1 layer of tape, item [3], to secure the winding in place. Primary Winding Start on pin(s) 3 and wind 72 turns of item [6] in 3.00 layer(s) from left to right. Add 1 layer of tape, item [4], in between each primary winding layer. At the end of 1st layer, continue to wind the next layer from right to left. At the end of 2nd layer, continue to wind the next layer from left to right. On the final layer, spread the winding evenly across entire bobbin. Finish winding on pin(s) 1. Add 1 layer of tape, item [3], for insulation. Bias Winding Start on pin(s) 5 and wind 10.0 turns (x 2 filar) of item [6]. Spread the winding evenly across entire bobbin. Finish on pin(s) 4. Add 1 layer of tape, item [3], for insulation. Primary Balanced Shield Winding Start on any (temp) pin on the secondary side and wind 7 turns (x 2 filar) of item [8]. Spread the winding evenly across entire bobbin. Finish this winding on pin(s) 1,2. Cut out wire connected to temp pin on secondary side. Leave this end of primary shield winding not connected. Bend the end 90 deg and cut the wire in the middle of the bobbin. Add 3 layers of tape, item [3], for insulation. Secondary Winding Start on pin(s) 10 and wind 8 turns (x 2 filar) of item [7]. Spread the winding evenly across entire bobbin. Finish on pin(s) 6. Add 2 layers of tape, item [3], for insulation. Core Assembly Assemble and secure core halves. Item [1]. Varnish Dip varnish uniformly in item [5]. Do not vacuum impregnate. Comments 1. For non-margin wound transformers use triple insulated wire for all secondary windings. Materials Item Description [1] Core: EI25, NC-2H or Equivalent, gapped for ALG of 133 nH/t^2 [2] Bobbin: Generic, 5 pri. + 5 sec. [3] Barrier Tape: Polyester film 9.80 mm wide [4] Separation Tape: Polyester film 9.8 mm wide [5] Varnish [6] Magnet Wire: 28 AWG, Solderable Double Coated [7] Triple Insulated Wire: 27 AWG [8] Magnet Wire: 27 AWG, Solderable Double Coated Electrical Test Specifications
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 10 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Parameter Condition Spec Electrical Strength, VAC 60 Hz 1 minute, from pins 1 - 5 to pins 6 - 10. 3000 Nominal Primary Inductance, uH Measured at 1 V pk-pk, typical switching frequency, between pin 1 to pin 3, with all other Windings open. 754 +/- 10% Primary Leakage, uH Measured between Pin 1 to Pin 3, with all other Windings shorted.
22.63 Goal
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6 Transformer Design Spread Sheet
Vout 1: 8.00 V, 3.00 A Vbias: 10.0 V, 0.006 A CLA MP 85-265 V AC Vin CinEMI Rectifier D S L C FX CONTROLCONTROL TOP245Y UV/OV ILim Feedback User Defined From Vout 1 RT N Design Results Power Supply Input Var Value Output 1. (main) Units Description VACMIN 85 Volts Min Input AC Voltage. VACMAX 265 Volts Max Input AC Voltage FL 50 Hertz Line Frequency TC 2.44 mSeconds Diode Conduction Time Z 0.57 Loss Allocation Factor N 77.0 % Efficiency Estimate Power Supply Outputs Var Value Output 1. (main) Units Description VOx 8.00 Volts Output Voltage IOx 3.00 Amps Output Current VB 10.0 Volts Bias Voltage IB 0.006 Amps Bias Current
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 12 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Device Variables Var Value Output 1. (main) Units Description Device TOP245Y PI Device Name PO 24.1 Watts Total Output Power VDRAIN 559 Volts Maximum Drain Voltage VDS 4.83 Volts Drain to Source Voltage FS 66000 Hertz Switching Frequency KRPKDP 0.78 Continuous/Discontinuous Operating Ratio KI 0.75 KI Factor ILIMITEXT 1.26 Amps Device Current Limit External Minimum ILIMITMIN 1.67 Amps Current Limit Minimum ILIMITMAX 1.93 Amps Current Limit Maximum IP 1.14 Amps Peak Primary Current IRMS 0.50 Amps Primary RMS Current DMAX 0.45 Maximum Duty Cycle Power Supply Components Selection Var Value Output 1. (main) Units Description VBRIDGE 600 Volts Diode Bridge Voltage Rating IAVG 0.32 Amps Average Diode Bridge Current CIN 100.0 uFarads Input Capacitance VMIN 98.6 Volts Minimum DC Input Voltage VMAX 374.8 Volts Maximum DC Input Voltage VCLO 130 Volts Clamp Zener Voltage PZ 1.3 Watts Primary Zener Clamp Loss VDB 0.70 Volts Bias Diode Forward Voltage Drop PIVB 61 Volts Bias Rectifier Max Peak Inverse Voltage Power Supply Output Parameters Var Value Output 1. (main) Units Description VDx 0.70 Volts Output Winding Diode Forward Voltage Drop PIVSx 50 Volts Output Rectifier
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 13 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Maximum Peak Inverse Voltage ISPx 10.01 Amps Peak Secondary Current ISRMSx 4.81 Amps Secondary RMS Current IRIPPLEx 3.76 Amps Output Capacitor RMS Ripple Current Transformer Construction Parameters Var Value Output 1. (main) Units Description Core/Bobbin EI25 Core Type Core Manuf. Generic Core Manufacturer Bobbin Manuf Generic Bobbin Manufacturer LP 686 uHenries Primary Inductance NP 71.7 Primary Number of Turns NB 9.8 Bias Winding Number of Turns AWG 28 AWG Primary Wire Gauge CMA 322 Cmils/A Primary Winding Current Capacity VOR 78.00 Volts Reflected Output Voltage BW 9.80 mm Bobbin Winding Width M 0.0 mm Safety Margin Width L 3.00 Primary Number of Layers AE 41.00 mm^2 Core Cross Sectional Area ALG 133 nH/T^2 Gapped Core Effective BM 2668 Gauss Maximum Flux Density BP 3369 Gauss Peak Flux density BAC 1041 Gauss AC Flux Density for Core Loss LG 0.362 mm Estimated Gap Length LL 10.3 uHenries Primary Leakage Inductance LSEC 20 nHenries Secondary Trace Inductance
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 14 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com LSEC 20 nHenries Secondary Trace Inductance Secondary Parameters Var Value Output 1. (main) Units Description NSx 8.0 Secondary Number of Turns Rounded Down NSx Rounded to Integer Secondary Number of Turns Rounded Down Vox Volts Auxiliary Output Voltage for Rounded down to Integer Secondary Number of Turns Rounded Up NSx Rounded to Next Integer Secondary Number of Turns Rounded Up Vox Volts Auxiliary Output Voltage for Rounded up to Next Integer Secondary Number of Turns AWGSx Range 17 - 21 AWG
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7 Performance Data
7.1 Line and Load Regulation
Figure 3 – Output Line/Load Regulation
7.2 Efficiency
Figure 4 – Efficiency
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8 Waveforms
8.1 Output Voltage Startup
Figure 5 – Vin = 90 VAC, LOAD = 3 A V: 2V/div; T: 2msec/div Figure 6 – Vin = 265 VAC, LOAD = 3 A V: 2V/div; T: 2msec/div
8.2 Drain Voltage / Current
Figure 7 – Vin = 90 VAC, LOAD = 3 A Top: Drain Current (1A/div) Bottom: Drain Voltage (100V/div); T: 5µsec/div Figure 8 – Vin = 265 VAC, LOAD = 3 A Top: Drain Current (1A/div) Bottom: Drain Voltage (200V/div); T: 5µsec/div
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8.3 Output Ripple Measurements
8.3.1 Ripple Measurement Technique
For DC output ripple measurements, a modifi ed oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 9 and Figure 10. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 µF/50 V ceramic type and one (1) 1.0 µF/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below). Figure 9 – Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed) Figure 10 – Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added). Probe Ground Probe Tip
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8.3.2 Output Voltage Ripple
Figure 11 – Output Ripple, 3 A Load, 90 VAC V: 200mV/div; T: 5µsec/div Figure 12 – Output Ripple, 3 A Load, 90 VAC V: 200mV/div; T: 2msec/div Figure 13 – Output Ripple, 3 A Load, 265 VAC V: 200mV/div; T: 5µsec/div Figure 14 – Output Ripple, 3 A Load, 265 VAC V: 200mV/div; T: 2msec/div
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9 EMI Tests
A conducted EMI scan of the prototype was taken to determine the effectiveness of the input filter and transformer ESHIELD® construction. The following plots show the peak spectra of the converter against quasi-peak (QP) and average (AVG) limits of EN55022 Class B. Both scans were taken at 120 VAC / 60Hz input with maximum load applied to the outputs. Since the peak scans are below the average limits, it is expected that the QP and Average scans would have greater than 10db of margin below the limits. Figure 15 – EMI Test Results, 3 A Load, 120 VAC (Line) Figure 16 – EMI Test Results, 3 A Load, 120 VAC (Neutral)
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 20 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Date Author Revision Description & changes Reviewed September 12, 2005 RSP 1.0 Initial Release AM / VC December 7, 2005 RSP 2.0 Edit schematic to see cut-off area VC
DER-100 24W Flyback Power Supply – TOP245 December 7, 2005 Page 21 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 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 oth ers. 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. © Copyright 2004, Power Integrations. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS
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