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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 title engineering prototype report for ep-29 - multiple output 11 w (15.5 w peak) ac-dc power supply using tny268p ( tinyswitch ? -ii ) specification universal input, 3.3 v, 5 v, 12 v, -12 v outputs application dvd player, cable box, dvb-t receiver author power integrations application department document number EPR-29 date 7-jul-03 revision 1.3 summary and features ? universal input operation (90 vac to 265 vac) ? high efficiency multiple output supply >79% (min.) ? high low-load efficiency ? low parts count solution ? good cross-regulation without linear post-regulators ? very low cost emi filter ? no common-mode choke 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 .
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 2 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com table of contents 1 introduction ................................................................................................................ 3 2 power supply specification........................................................................................ 4 3 schematic .................................................................................................................. 5 4 circuit descr iption ...................................................................................................... 6 4.1 input emi filtering............................................................................................... 6 4.2 tinyswitch-ii primary .......................................................................................... 6 4.3 output rectification............................................................................................. 6 4.4 output feedback ................................................................................................ 7 5 pcb layout................................................................................................................ 8 6 bill of mate rials .......................................................................................................... 9 7 transformer specification ........................................................................................ 10 7.1 electrical diagram............................................................................................. 10 7.2 electrical spec ifications .................................................................................... 10 7.3 materials ........................................................................................................... 11 7.4 transformer build diagram ............................................................................... 11 7.5 copper foil preparation .................................................................................... 12 7.6 winding instructions.......................................................................................... 12 8 transformer spreadsheet ........................................................................................ 14 9 performance data .................................................................................................... 17 9.1 efficiency........................................................................................................... 17 9.2 no-load input power ......................................................................................... 17 9.3 standby input power......................................................................................... 18 9.4 regulation......................................................................................................... 19 9.4.1 load regulation......................................................................................... 19 9.4.2 line regulation.......................................................................................... 22 10 thermal performance........................................................................................... 23 11 waveforms ........................................................................................................... 24 11.1 drain voltage and curren t, normal operation .................................................. 24 11.2 output voltage start-up profiles ....................................................................... 24 11.2.1 start-up profile for 3.3 v and 5 v outputs.................................................. 24 11.3 drain voltage and current start-up profile ....................................................... 25 11.4 load transient response (75% to 100% load step) ....................................... 26 11.4.1 transient response for 3.3 v and 5 v outputs ......................................... 26 11.4.2 transient response for +12 v and ?12 v outputs .................................... 27 11.5 output ripple measurements ........................................................................... 28 11.5.1 ripple measur ement technique ................................................................ 28 11.5.2 ripple measur ements at 115 vac............................................................. 29 11.5.3 ripple measur ements at 230 vac............................................................. 30 11.6 conducted emi ................................................................................................. 31 12 revision history.................................................................................................... 32 important note: although the ep-29 board is designed to satisfy safety isolation requirements, this 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.
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 3 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 1 introduction this document is an engineering report describing an 11 w universal input, multiple output flyback power supply, utilizing a tny268p device from the tinyswitch-ii family. this power supply is intended to allow evaluation in such applications as dvd players, cable and dvb-t set-top boxes. as some a pplications have peak loads, accelerating a dvd disc up to speed for example, this s upply will deliver 11 w continuously and up to 15.5 w peak (thermally limited). the document contains the pow er supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. figure 1 ? ep-29 populated circuit board photograph. note: minimum loads are not provided on the board, hence for correct operation all outputs should be loaded according to the specification table.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 4 of 36 power integrations, inc. 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 v in 90 265 vac 2 wire ? no protective earth ground frequency f line 47 50/60 64 hz standby input power 0.8 0.9 w 0.55 w load (see below) no-load input power 0.09 0.1 w zero load, measured at 230 vac output (normal operation) output voltage 1 v out1 3.2 3.3 3.4 v 5% output ripple voltage 1 v ripple1 50 mv p-p, 20 mhz bandwidth output current 1 i out1 0.3 0.6 0.7 a output voltage 2 v out2 4.75 5 5.25 v 5% output ripple voltage 2 v ripple2 75 mv p-p, 20 mhz bandwidth output current 2 i out2 0.5 1.2 1.45 a output voltage 3 v out3 11.16 12 12.84 v 7% output ripple voltage 3 v ripple3 100 mv p-p, 20 mhz bandwidth output current 3 i out3 0.1 0.2 0.4 a output voltage 4 v out4 -11.16 -12 -12.84 v 7% output ripple voltage 4 v ripple4 100 mv p-p, 20 mhz bandwidth output current 4 i out4 0.03 0.05 0.1 a total output power continuous output power p out 11 w at maximum ambient temperature peak output power p out_peak 15.5 w thermally limited efficiency 75 % at p out (15.5 w), 25 o c output (standby) output voltage 1 v out1(sb) 3.2 3.3 3.4 v 5% output current 1 i out1(sb) - 0.02 - a output voltage 2 v out2(sb) 4.75 5 5.25 v 5% output current 2 i out2(sb) - 0.1 - a output voltage 3 v out3(sb) 11.16 12 13.2 v -7% / +15% output current 3 i out3(sb) 2 - - ma output voltage 4 v out4(sb) -11.16 -12 -13.2 v -7% / +15% output current 4 i out4(sb) 2 - - ma environmental conducted emi meets cispr22b / en55022b safety designed to meet iec950, ul1950 class ii surge 2 kv 1.2/50 s surge, iec 1000-4-5, 2/12 ? series impedance, differential/common mode ambient temperature t amb 0 50 o c free convection, sea level
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 5 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 3 schematic figure 2 ? ep-29 schematic.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 6 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 4 circuit description the circuit shown is an ac to dc multi-output flyback power supply using the highly integrated tny268 power ic from the tinyswitch-ii family. the circuit is designed for 90 vac to 265 vac input with 3.3 v, 5 v, 12 v, and -12 v outputs. 4.1 input emi filtering capacitor c3, inductor l1 and capacitors c1 and c4 provide differential mode emi filtering. capacitor c8 (y-capacitor) helps to reduce common-mode and radiated emi. in conjunction with these components, the frequency jitter feature of the tny268 and shields in the transformer, allow the unit to pass cispr22b/en55022b specifications for conducted emissions without the need for a common-mode choke. 4.2 tinyswitch-ii primary diodes d1, d2, d3, and d4 and capacitors c1 and c4 provide a high-voltage dc bus for the primary circuitry. the dc bus is applied to the high side of the transformer t1 primary winding. the other side of the transformer primary is driven by the integrated switching mosfet of the tinyswitch-ii u1. components d5, r5, c2, r7, and vr1 form the clamp network to limit the voltage rise at mosfet turn-off due to the transformer leakage inductance. this circuit clamps the mosfet voltage to a safe level during normal power supply operation. the zener vr1 actively clamps at peak output load, but does not contribute to the clamping at normal load conditions. diode d5 is a slow-recovery diode and allows some of the clamp energy to be recovered and transferred to the output. after clamping the leakage inductance energy, diode d5 does not turn off immediately. this allows some current to flow in the reverse direction, out of c2 and couple through the transformer to the secondary side. resistors r5 and r7 damp ringing while r5 also limits the reverse current through d5 when u1 turns on. the energy recovery of this clamp scheme contributes to slightly higher efficiency and also better cross-regulation. diode d9 and capacitor c10 rectify and filter the voltage from the transformer bias winding. current is fed from c10 via r6 to the bypass pin of u1. supplying u1 from the bias winding reduces power consumption by inhibiting the internal drain current source normally used to power the ic from the high voltage dc bus during the internal mosfet off time. this helps improve the no-load power consumption and light load efficiency of the power supply. capacitor c19 is the decoupling capacitor for the tinyswitch-ii . opto-transistor u2a provides feedback from the secondary side to control tinyswitch-ii regulation. 4.3 output rectification diodes d7, d11, d10, and d8 together with capacitors c15, c11, c12, and c9 provide rectification and filtering of the secondary transformer voltages. capacitors c20, c17, and c18 with inductors l2, l3, and l4 provide filtering to reduce high switching frequency
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 7 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com ripple from the outputs. this is implemented with resistor r12 and capacitor c6 on the lower current ?12 vdc output. 4.4 output feedback resistors r15 and r16 sense the 5 v and 3.3 v outputs and with resistor r13 form a voltage divider network at the input of the tl431 (u3). capacitor c14 provides compensation for the tl431 (to provide high dc gain but low high frequency gain). the tl431 drives current through optocopler led u2b, which in turn is fed from the 5 v rail (before the post filter) by resistor r9. the value of r9 programs the high frequency gain of the control loop. the on/off control scheme used by tinyswitch-ii (u1) ensures low output ripple, fast transient response, high low-load efficiency, and low no-load consumption while minimizing audible noise by ensuring the transformer flux density is low when the switching frequency enters the audible range. capacitor c7 provides a soft-finish characteristic to ?close? the feedback loop early during power up, thus eliminating startup output ov ershoot. resistor r8 provides a discharge path for c7 after power down.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 8 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 5 pcb layout figure 3 ? printed circuit layout (dimensions 0.001 ).
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 9 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 6 bill of materials ep-29 - tny268 dvd 11 w (15.5 w pk) ? 050203b item qty reference description p/n manufacturer 1 2 c1, c4 33 f, 400 v kmg400vb33m nippon chemi-con 16 mm x 25 mm, general purpose 2 1 c2 0.01 f, 1 kv, ceramic z5u dielectric any 3 1 c3 0.047 f, x2 class any 4 2 c6, c9 220 f, 25 v kmg25vb220m nippon chemi-con 8 mm x 11.5 mm, general purpose 5 2 c7, c10 10 f, 50 v kmg50vb10m nippon chemi-con 5 mm x 11 mm, general purpose 6 1 c8 1 nf, y1 class (safety) any 7 1 c11 1800 f, 25 v, 24 m ? ky25vb1800mk30 nippon chemi-con 12.5 mm x 30 mm, low esr 8 1 c12 1000 f, 10 v, 60 m ? ky10vb1000mj16 nippon chemi-con 10 mm x 16 mm, low esr 9 2 c14, c19 0.1 f, 50 v, ceramic z5u dielectric any 10 3 c15 470 f, 25 v, 38 m ? kze25vb470mj16 nippon chemi-con 10 mm x 16 mm, low esr 11 2 c17, c18 470 f, 10 v kmg10vb470m nippon chemi-con 8 mm x 11.5 mm, general purpose 12 1 c20 100 f, 25 v kmg25vb100m nippon chemi-con 6.3 mm x 11 mm, general purpose 13 4 d1, d2, d3, d4 1 a, 600 v 1n4007 any 14 1 d5 1 a, 600 v, glass passivated 1n4007gp vishay / any 15 2 d8, d7 uf4003 any 16 1 d9 1n4148 any 17 2 d10, d11 1n5822 any 18 1 f1 3.15 a, 250 vac any 19 1 l1 1.5 mh 0.25 a sbc3-152-251 tokin, or equiv. 20 3 l2, l3, l4 3.3 h, 2.66 a 822ly-3r3m toko, or equiv. 21 1 r5 47 ? , 1/4 w, 5% any 22 1 r6 3.3 k ? , 1/4 w, 5% any 23 1 r7 100 ? , 1/2 w, 5% any 24 1 r8 1 k ? , 1/4 w, 5% any 25 1 r9 200 ? , 1/4 w, 5% any 26 1 r12 1 ? , 1/2 w, 5% any 27 1 r13 10 k ? , 1/4 w, 1% any 28 1 r15 20 k ? , 1/4 w, 1% any 29 1 r16 6.34 k ? , 1/4 w, 1% any 30 1 t1 eel25 sil6026 hical 31 1 u1 tinyswitch-ii tny268p power integrations 32 1 u2b, u2a pc817a isocom / any 33 1 u3 tl431ac any 34 1 vr1 p6ke180 vishay / any 35 1 j1 header 26-48-1031 molex 0.156 spacing, 3 position (pull middle pin) 36 1 j2 header molex 0.156 spacing, 8 position 37 1 ep-29 printed circuit board, rev a
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 10 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7 transformer specification 7.1 electrical diagram 64t x 2 1 6 7 4 14 1t 13 9 7t x 4 11, 12 2t 4t x 4 8 bias primary 6t x 4 nc 5 shield 1 32t x 2 7 nc 4t x 4 shield 2 +12 v +5 v +3.3 v -12 v w3 w2 w1 w4 w5 w7 w6 w8 figure 4 ?transformer electrical diagram. 7.2 electrical specifications electrical strength 1 second, 60 hz, from pins 1-7 to pins 8-14 3000 vac primary inductance pins 1-4, all other windings open. measured at 132 khz, 1 v rms 1.33 mh -0 / +15% resonant frequency pin 1-4, all other windings open 300 khz (min.) primary leakage inductance pins 1-4, with pins 8-14 shorted. measured at 132 khz, 1 v rms 30 h (max.)
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 11 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7.3 materials item description [1] core: eel25, tdk gapped for al of 320 nh/t 2 [2] bobbin: eel25 vertical 14 pins [3] magnet wire: # 32 awg [4] teflon tubing # 22 [5] copper foil 0.12 mm thick, 14 mm wide. [6] tape: 3m 1298 polyester film, 16.1 mm wide [7] tape: 3m 1298 polyester film, 22.1 mm wide [8] tape: 3m # 44 polyester web. 3.0 mm wide [9] copper tape 2.0 mils thick, 16 mm wide. [10] varnish 7.4 transformer build diagram pin side +12 v -12 v 4 1 6 13 11 7 12 14 9 primary bias +3.3 v and +5 v nc 8 5 nc shield 1 7 shield 2 13 nc = no connection to a pin figure 5 ? transformer build diagram.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 12 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7.5 copper foil preparation the following figure shows the copper foils to be used for +3.3 v and +5 v outputs (w6 and w7) +3.3 v out 2t copper foil 14.0 mm wide. 0.12 mm thick. start pin 11 connect pin 9 finish pin 13 105 mm 45 mm +5 v out 1t copper foil 14.0 mm wide. 0.12 mm thick. #26 copper wire #26 copper wire figure 6 ? foil winding preparation diagram. 7.6 winding instructions bobbin set up orientation set up the bobbin with its pins oriented to the right hand side. margin tape apply 3.0 mm margin at each side of bobbin using item [8]. match combined height of primary, shield and bias windings. w1 first shield start with a floating lead. wind 32 bifilar turns of item [3] from left to right. wind tightly and uniformly across entire width of bobbin. finish at pin 5 using item [4] at the finish leads. cut the starting lead just at the starting of the winding. basic insulation apply one layer of tape item [6]. w2 two layers primary start on pin 1 using item [4] at the start leads. wind 32 bifilar turns of item [3] from right to left . apply one layer of item [6]. continue the same wire on second layer. wind 32 turns from left to right. the two layers should be wound tightly with the turns uniformly distributed across entire width of bobbin. finish on pin 4 using item [4] at the finish leads. basic insulation apply one layer of tape item [6]. w3 bias start on pin 7 using item [4] at the start leads. wind 6 turns of 4 parallel wires of item [3]. wind from right to left in a single layer. the wires should be wound tightly and uniformly spread across the bobbin width. finish on pin 6 using item [4] at the finish leads. basic insulation apply one layer of tape item [6]. w4 second shield. start with a floating lead. wind 4 turns of 4 parallel wires of item [3]. wind from right to left in a single layer. the wires should be wound tightly and uniformly spread across the bobbin width. finish on pin 7 using item [4] at the finish leads. cut the starting lead just at the starting of the winding. insulation 3 layers of tape [7] for insulation. margin tape apply 3.0 mm margin at each side of bobbin using item [8]. match combined height of secondary windings. w5 +12 v out start on pin 13 using item [4] at the start leads. wind tightly 4 turns of 4 parallel wires of item [3]. wind from right to left in a single spread across the bobbin width. finish on pin 8 using item [4] at the finish leads. basic insulation apply one layer of tape item [6].
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 13 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com w6 and w7 +3.3 v and +5 v outputs. prepare copper foil item [5] and item [7] as shown in figure 6. start at pin 11 using item [4] at the start leads. wind 2 turns. connect the second lead to pin 9 using item [4] at the finish leads. wind 1 turn. connect the end lead to pin 13 using item [4] at the finish leads. basic insulation apply one layer of tape item [6]. w7 -12 v output. start at pin 14 using item [4] at the start leads. wind 7 turns of 4 parallel wires of item [3]. wind tightly from right to left in a uniform spread across the bobbin width. finish on pin 12 using item [4] at the finish leads. outer insulation 3 layers of tape [7] for insulation. core assembly assemble and secure core halves. item [1]. belly band/ flux band wind copper tape item [9] outside of core halves. outer insulation wrap the core right over the belly band with three layers item [7]. final assembly dip varnish uniformly in item [10]. do not vacuum impregnate. note: vacuum impregnation may require re-optimization of shield windings for acceptable emi performance.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 14 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8 transformer spreadsheet design warning (n o optimization) power supply input vacmin volts 90 min input ac voltage vacmax volts 265 max input ac voltage fl hertz 50 ac main frequency tc mseconds 2.21 bridge rectifier conduction time estimate z 0.52 loss allocation factor n % 79.0 efficiency estimate power supply outputs vox volts 3.30 5.00 12.00 12.00 output voltage iox amps 0.700 1.450 0.400 0.100 output current device variables device tny268p/g device name po watts 15.56 total output power warning! device may be too small or thermally limited for continuous power level (po). tip: consider increasing device size. if p/g or r- package select larger device (reduce current limit via x-pin) or choose y/f-package with appropriat vdrain volts 643 maximum drain voltage estimate (includes effect of leakage inductance) vds volts 2.9 device on-state drain to source voltage fsnom hertz 132000 tinyswitch-ii switching frequency fsmin hertz 120000 tinyswitch- ii minimum switching frequency (inc. jitter) fsmax hertz 144000 tinyswitch-ii maximum switching frequency (inc. jitter) krpkdp 0.61 ripple to peak current ratio ilimitmin amps 0.51 device current limit minimum ilimitmax amps 0.59 device current limit maximum irms amps 0.27 primary rms current dmax 0.53 maximum duty cycle
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 15 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com power supply components selection cin ufarads 66.0 input filter capacitor vmin volts 107 minimum dc input voltage vmax volts 375 maximum dc input voltage vclo volts 170 clamp zener voltage pz watts 1.8 estimated primary zener clamp loss power supply output parameters vdx volts 0.5 0.5 0.7 0.7 output winding diode forward voltage drop pivsx volts 15 23 53 53 output rectifier maximum peak inverse voltage ispx amps 2.36 4.90 1.35 0.34 peak secondary current isrmsx amps 1.16 2.41 0.66 0.17 secondary rms current iripplex amps 0.93 1.92 0.53 0.13 output capacitor rms ripple current transformer construction parameters core/bobbin eel25 core and bobbin type core manuf. generic core manufacturing bobbin manuf generic bobbin manufacturing lpmin uhenries 1309 minimum primary inductance np 64 primary winding number of turns awg awg 32 primary wire gauge (rounded to next smaller standard awg value) cma cmils/a 237 primary winding current capacity vor volts 118.00 reflected output voltage bw mm 22.00 bobbin physical winding width warning! large bobbin width (bw) may lead to increased audio emissions. tip: reduce the bobbin width, or length, of the core. consider changing to an alternate device family (if using tinyswitch-ii). m mm 3.0 safety margin width l 1.1 number of primary layers ae cm^2 0.40 core effective cross section area alg nh/t^2 319 gapped core effective inductance bm gauss 3087 maximum operating flux density bac gauss 818 ac flux density for core curves
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 16 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com lg mm 0.12 gap length ll uhenries 26.2 estimated transformer primary leakage inductance lsec nhenries 20 estimated secondary trace inductance secondary parameters nsx 2.07 3.00 6.93 6.93 secondary number of turns rounded down nsx 2 6 6 rounded to integer secondary number of turns rounded down vox volts 3.17 10.30 10.30 auxiliary output voltage for rounded to integer nsx rounded up nsx 3 7 7 rounded to next integer secondary number of turns rounded up vox volts 5.00 12.13 12.13 auxiliary output voltage for rounded to next integer nsx awgsx range awg 23 - 27 20 - 24 25 - 29 31 - 35 secondary wire gauge range 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).
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 17 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9 performance data all measurements performed at room temperature, 60 hz input frequency. full load is: 3.3 v, 0.7 a; 5 v, 1.6 a; +12 v, 0.4 a; -12 v, 0.1 a. 9.1 efficiency ep-29 efficiency vs. input voltage 78% 79% 80% 81% 82% 83% 84% 80 100 120 140 160 180 200 220 240 260 280 ac input voltage (v rms) efficiency (%) pout = 17 w pout = 10 w figure 7 - efficiency vs. input voltage, room temperature, 60 hz. 9.2 no-load input power ep-29 no-load input power vs. line 0 10 20 30 40 50 60 70 80 90 100 80 130 180 230 280 ac input voltage (v rms) no-load input power (mw rms) 3.3 v and 5 v outputs unloaded 12 v and -12 v outputs 6 k ? figure 8 - zero load input power vs. input line voltage, room temperature, 60 hz. ep-29 no-load input power vs. line
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 18 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.3 standby input power ep-29 standby input power vs. line 0.55 w output load 500 550 600 650 700 750 800 850 900 950 1000 80 130 180 230 280 ac input voltage (v rms) no-load input power (mw rms) 3.3 v, 20 ma; 5 v, 100 ma 12 v and -12 v, 2 ma figure 9 - standby input power vs. input line voltage, room temperature, 0.55 w load, 60 hz. ep - 29 standby input power vs. line 0.55 w output load
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 19 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.4 regulation 9.4.1 load regulation load regulation data was taken at four load conditions: (1) 3.3 v and 5 v min. load, (2) 3.3 v typ. load, 5 v min. load, (3) 3.3 v min. load, 5 v typ. load, and (4) 3.3 v and 5 v max. load. ep-29 load regulation, 3.3 v 95% 97% 99% 101% 103% 105% 8 1012141618 p out (w) regulation (% of nominal) 85 vac, 3.3 v 115 vac, 3.3 v 230 vac, 3.3 v 265 vac, 3.3 v figure 10 ? load regulation, 3.3 v, room temperature.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 20 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com ep- 29 load regulation, 5 v 95% 97% 99% 101% 103% 105% 8 1012141618 p out (w) regulation (% of nominal) 85 vac, 5 v 115 vac, 5 v 230 vac, 5 v 265 vac, 5 v figure 11 ? load regulation, 5 v, room temperature. ep-29 load regulation, +12 v 95% 97% 99% 101% 103% 105% 8 1012141618 p out (w) regulation (% of nominal) 85 vac, +12 v 115 vac, +12 v 230 vac, +12 v 265 vac, +12 v figure 12 ? load regulation, +12 v, room temperature.
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 21 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com ep-29 load regulation, -12 v 95% 97% 99% 101% 103% 105% 8 1012141618 p out (w) regulation (% of nominal) 85 vac, -12 v 115 vac, -12 v 230 vac, -12 v 265 vac, -12 v figure 13 ? load regulation, -12 v, room temperature.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 22 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.4.2 line regulation ep-29 line regulation, full load 95.0% 97.0% 99.0% 101.0% 103.0% 105.0% 80 100 120 140 160 180 200 220 240 260 280 ac input voltage (v rms) regulation (% of nominal) 3.3 v 5 v +12 v -12 v figure 14 ? line regulation, room temperature, full load.
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 23 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 10 thermal performance a thermal image was taken of a unit painted matt black to indicate component temperatures. in a ddition a thermocouple was attached at the source pins of u1 to provide a more accurate measurement. for reference the board silk screen has been overlaid. figure 15 ? ep-29 thermal performance. ambient temperature was 23 c. the source pins of u1 were measured to be 54 c at pin 7 and 8 under typical load (11 w) and 90 vac input. the hottest component on the board can be seen to be d11 at approximately 60 c. these results are acceptable; under high ambient conditions all components would be expected to remain below 100 c.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 24 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11 waveforms 11.1 drain voltage and current, normal operation figure 16 - 115 vac, full load. upper: i drain , 0.2 a, 2 s / div lower: v drain , 200 v, 2 s / div figure 17 - 230 vac, full load upper: i drain , 0.2 a, 2 s / div lower: v drain , 200 v, 2 s / div 11.2 output voltage start-up profiles 11.2.1 start-up profile for 3.3 v and 5 v outputs figure 18 - start-up profile, 115 vac upper plot: 5 v out , 2 v / div. middle plot: 3.3 v out , 2 v / div. lower plot: i drain , 0.2 a, 2 s /div. figure 19 - start-up profile, 230 vac upper plot: 5 v out , 2 v / div. middle plot: 3.3 v out , 2 v / div. lower plot: i drain , 0.2 a, 2 s /div.
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 25 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com figure 20 - start-up profile, 115 vac upper plot: +12 v out , 5 v / div. middle plot: -12 v out , 5 v / div. lower plot: i drain , 0.2 a, 2 s /div. figure 21 - start-up profile, 230 vac upper plot: +12 v out , 5 v / div. middle plot: -12 v out , 5 v / div. lower plot: i drain , 0.2 a, 2 s /div. 11.3 drain voltage and cu rrent start-up profile figure 22 - 115 vac input and maximum load. upper: v drain , 200 v / div. lower: i drain , 0.2 a & 2 ms / div. figure 23 - 265 vac input and maximum load. upper: v drain , 200 v / div. lower: i drain , 0.2 a & 2 ms / div.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 26 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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. 11.4.1 transient response for 3.3 v and 5 v outputs figure 24 ? transient response, 115 vac, 75-100-75% load step on 5 v upper: 5 v load current, 0.5 a / div. middle: 3.3 v output, 50 mv / div. lower: 5 v output, 50 mv / div. all 500 s / div. figure 25 ? transient response, 230 vac, 75-100-75% load step on 5 v upper: 5 v load current, 0.5 a / div. middle: 3.3 v output, 50 mv / div. lower: 5 v output, 50 mv / div. all 500 s / div.
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 27 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.4.2 transient response for +12 v and ?12 v outputs figure 26 ? transient response, 115 vac, 75-100-75% load step on 5 v upper: 5 v load current, 0.5 a / div. middle: +12 v output, 50 mv / div. lower: -12 v output, 50 mv / div. all 500 s / div. figure 27 ? transient response, 230 vac, 75-100-75% load step on 5 v upper: 5 v load current, 0.5 a / div. middle: +12 v output, 50 mv / div. lower: -12 v output, 50 mv / div. all 500 s / div.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 28 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5 output ripple measurements 11.5.1 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 28 and figure 29. 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). figure 28 - oscilloscope probe prepared for ripple measurement (end cap and ground lead removed). figure 29 - 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
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 29 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5.2 ripple measurements at 115 vac figure 30 ? 3.3 v ripple, 115 vac, full load 2 ms, 50 mv / div. 19 mv p-p figure 31 ? 5 v ripple, 115 vac, full load 2 ms, 50 mv / div. 52 mv p-p figure 32 ? 12 v ripple, 115 vac, full load 2 ms, 50 mv / div. 29 mv p-p figure 33 ? -12 v ripple, 115 vac, all outputs at full load. 2 ms, 50 mv / div. 42 mv p-p
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 30 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5.3 ripple measurements at 230 vac figure 34 ? 3.3 v ripple, 230 vac, full load. 2 ms, 50 mv / div. 18 mv p-p figure 35 ? 5 v ripple, 230 vac, full load. 2 ms, 50 mv / div. 48 mv p-p figure 36 ? 12 v ripple, 230 vac, full :oad. 2 ms, 50 mv/div. 16 mv p-p figure 37 ? -12 v ripple, 230 vac, full load. 2 ms, 50 mv/div. 40 mv p-p
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 31 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.6 conducted emi both measurements were taken with the artificial hand input on the lisn connected to output return. the results represent the worst case with respect to line and load conditions. in both cases >10 db margin exists indicating very acceptable performance. figure 26 ? conducted emi, 15 w peak load, 115 vac, 60 hz, and en55022 b limits. figure 27 ? conducted emi, 15 w peak load, 230 vac, 60 hz, and en55022 b limits.
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 32 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 12 revision history date author revision description & changes 08/08/02 vc 0.1 original document. 12/03/02 vc 0.12 update transformer document 5/2/03 rm 0.90 cleaned up all pages thru transformer section. added layout, bom, and revised all description text. 5/14/03 rm 0.91 measurements / waveforms all re-taken. new data inserts and formatted. 5/14/03 rm 0.92 xfmr spreadsheet included. doc released for review 5/21/03 pv 0.95 to 0.98 corrected circuit description, revised spec, transformer design to meet krp limits 06/15/03 im 1.0 first release 06/19/03 pv 1.1 updated bom/schematic to remove r10 in series with c14 - not on pcb design. 06/20/03 pv 1.2 added thermal, no-load and standby data, corrected l1 on schematic, added regulation test setup description. 07/07/03 pv 1.3 updated power supply specification table data for the output current 2.
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 33 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com notes
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 34 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com notes
07-july-03 EPR-29 ? 4 output, 11 w, universal input, dvd supply page 35 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com notes
EPR-29 ? 4 output, 11 w, universal input, dvd supply 07-july-03 page 36 of 36 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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. ? 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 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 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. 5f-1 no. 316 nei hu road sec. 1, nei hu dist. taipei, taiwan 114, r.o.c. phone: +886-2-2659-4570 fax: +886-2-2659-4550 e-mail: taiwansales@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 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 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 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 applications hotline world wide +1-408-414-9660 applications fax world wide +1-408-414-9760

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