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power integrations 5245 hellyer avenue, san jose, ca 95138 usa. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com title reference design report for active discharging of the x capacitor for reduced no-load power consumption using capzero ? cap014dg specification 85 vac ? 264 vac input application general purpose author applications engineering department document number rdr-252 date april 14, 2010 revision 1.0 summary and features ? very low no-load input power (<5 mw actual dissipation) ? passes surge testing to en6100-4-5 class 4 (2 kv dm / 4 kv cm) ? safely discharges the x capacitor with a time constant of less than 1 second. patent information the products and applications illustrated herein (including transf ormer construction and circuits external to the products) may be covered by one or more u.s. and foreign patents, or potentially by pendi ng u.s. and foreign patent applications assigned to power integ rations. a complete list of power integrations' patents may be found at www. powerint.com. power integrations grants its customers a licens e under certain patent rights as set forth at .
rdr-252 - capzero reference design board 14-apr-10 page 2 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com table of contents 1 introducti on.................................................................................................................3 2 specificat ion ...............................................................................................................4 3 schemat ic...................................................................................................................5 4 circuit desc ription ......................................................................................................6 5 pcb lay out ................................................................................................................7 6 bill of ma terials ...........................................................................................................8 7 no-load input power performance .............................................................................9 7.1 capzero ic consumption (x capacit or + mov removed from board)...........10 7.2 no-load consumption including effe ct of x capacit or and mov.......................11 7.3 no-load input power including mov and ca pzero (x capacitor removed) ....12 8 x capacitor dischar ge wavefo rms...........................................................................13 8.1 ac disconnect at r oom temper ature...............................................................13 8.2 ac disconnect at 105 o c ambien t.....................................................................13 8.3 ac disconnect at -5 o c ambi ent .......................................................................14 8.4 input arcing test r oom temper ature ...............................................................15 8.5 ac input arcing test at 105 o c ambi ent ...........................................................17 8.6 ac input arcing test at -5 o c ambi ent ..............................................................19 9 ac surge and ring wave te st.................................................................................21 9.1 ring wave test.................................................................................................21 9.2 differential mode surge, 1.2 / 50 ? sec ..............................................................21 9.3 common mode surge, 1.2 / 50 ? sec.................................................................21 9.4 ac disconnect test after su rge........................................................................22 10 emi test s..............................................................................................................23 11 revision hi story ....................................................................................................25 important note: although this board is designed to satisfy safe ty isolation requirements, the engineering prototype has not been agency appr oved. therefore, all testing should be performed using an isolation transformer to provide the ac input to the prototype board.
14-apr-10 rdr-252 - capzero reference design board page 3 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 1 introduction this engineering report describes a capzero ? demonstration board employing the power integrations cap014dg. this demons tration board operates over a universal input range. it has been designed and test ed to operate with an ambient temperature environment of up to 105 c. this document provides complete design deta ils including specifications, the schematic, bill of materials. this information includes performance results, surge tests and emi scans. figure 1 ? populated circuit board photograph, component side. figure 2 ? populated circuit board photograph, solder side.
rdr-252 - capzero reference design board 14-apr-10 page 4 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 2 specification the table below represents the minimum acc eptable performance of the design. actual performance is listed in the results section. description symbol min typ max units comment input voltage v in 85 264 vac 2 wire ? no p.e. frequency f line 47 50/60 63 hz no-load input power (230 vac) 0.08 w including mov leakage and reactive current generated input cable losses rc discharge time constant 1 second conducted emi meets cispr22b / en55022b safety designed to meet iec950 / ul1950 class ii line surge differential mode (l1-l2) common mode (l1+l2-pe) 2 4 kv kv 1.2/50 ? s surge, iec 1000-4-5, series impedance: differential mode: 2 ? common mode: 12 ? ring wave test differential mode (l1-l2) 1 kv 1.2/50 ? s surge, iec 1000-4-5, series impedance: differential mode: 2 ? ambient temperature t amb -5 105 o c free convection, sea level
14-apr-10 rdr-252 - capzero reference design board page 5 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 3 schematic figure 3 ? schematic. *note: c1a and c1c are optional comp onents and are not populated on this board. these allow the board to be used in conjunction wit h larger or smaller x capacitors to test the functionality of larger or smaller devices.
rdr-252 - capzero reference design board 14-apr-10 page 6 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 4 circuit description during normal operation, the controller within u1 detects the presence of ac input by detecting that the voltage between d1 and d2 is re versing polarity at fixed time intervals. failure to detect polarity reversal is an indica tion of removal of ac input. this is used as a signal to turn on the mosfets within u1 and discharge the x capacitor. the values of resistors are chosen to guarantee that the ti me constant of t he x capacitor and the discharge resistors is less than 1 second.
14-apr-10 rdr-252 - capzero reference design board page 7 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 5 pcb layout figure 4 ? printed circuit board layout.
rdr-252 - capzero reference design board 14-apr-10 page 8 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 6 bill of materials item qty ref des description mfg part number manufacturer 1 1 c1 1 ? f, 275 vac, polyester film, x2 bfc2 338 20105 vishay bc components 2 1 f1 2 a, 250 v, slow, tr5 3721200041 wickman 3 1 j1 3 position (1 x 3) header, 0.156 pitch, vertical 26-48-1031 molex 4 2 r1 r2 390 k ? , 5%, 1/4 w, thick film, 1206 erj-8geyj394v panasonic 5 1 rv1 320 v, 14 mm, radial s14k320 littlefuse 6 1 u1 capzero, cap014dg, so-8 cap014dg power integrations
14-apr-10 rdr-252 - capzero reference design board page 9 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7 no-load input power performance to correctly measuring the no-load input pow er of the capzero device itself the x capacitor and mov should be remo ved from the board. the presence of the x capacitor causes reactive currents which flow in the input cables. this results in a real power loss component which is them measured by the ac power meter. therefor e to eliminate this error when measuring the power consumption of the capzero ic the capacitor should be removed. the mov has a small leakage current which also generates a power loss measured by the power meter so again should be remov ed to correctly measure the capzero consumption. to illustrate these effects power cons umption was measured with and without the capacitor and mov fitted. input line mov and x capacitor removed (mw) mov removed (mw) all components present (mw) 85 v / 50 hz 1.5 1.5 2 100 v / 50 hz 1.7 1.9 2.8 115 v / 60 hz 2 2.3 3 132 v / 60 hz 2.3 2.8 4.8 230 v / 50 hz 4 5.7 8 240 v / 50 hz 4.1 6.1 11 265 v / 50 hz 4.6 7.5 12
rdr-252 - capzero reference design board 14-apr-10 page 10 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7.1 capzero ic consumption (x capacitor + mov removed from board) no-load power is measured at room temper ature without x capacit or c1b or mov rv1 fitted. this data repres ents the true consumpti on of the capzero ic. 1 1.5 2 2.5 3 3.5 4 4.5 5 80 100 120 140 160 180 200 220 240 260 input voltage (vac) power (mw) 50 hz 60 hz figure 5 ? no-load input power vs. input line voltage, room temperature, 60 hz. input line p in (mw) 85 v / 50 hz 1.5 100 v / 50 hz 1.7 115 v / 60 hz 2.0 132 v / 60 hz 2.3 230 v / 50 hz 4 240 v / 50 hz 4.1 265 v / 50 hz 4.6 table 1 ? no-load input power vs. input voltage with x capacitor and mov removed.
14-apr-10 rdr-252 - capzero reference design board page 11 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7.2 no-load consumption including effect of x capacitor and mov the following measurements include cable loss as a result of the reac tive current drawn by the x capacitor and leak age current of the mov. 1 3 5 7 9 11 13 80 100 120 140 160 180 200 220 240 260 input voltage (vac) power (mw) 50 hz 60 hz figure 6 ? no-load input power with x capacitor populated on board. input line p in (mw) 85 v / 50 hz 2 115 v / 50 hz 2 175 v / 50 hz 5 230 v / 50 hz 8 265 v / 50 hz 11 85 v / 60 hz 2 115 v / 60 hz 3 175 v / 60 hz 5 230 v / 60 hz 9 265 v / 60 hz 12 table 2 ? no-load input power vs. input voltage including effect of x capacitor and mov.
rdr-252 - capzero reference design board 14-apr-10 page 12 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7.3 no-load input power including mov and capzero (x capacitor removed) following measurements are with the x capacitor remov ed. mov and capzero ic were on the board. 1 2 3 4 5 6 7 8 80 100 120 140 160 180 200 220 240 260 input voltage (vac) power (mw) figure 7 ? no-load input power vs. input line voltage, room temperature, 60 hz. input line p in (mw) 85 v / 50 hz 1.5 100 v / 50 hz 1.9 115 v / 60 hz 2.3 132 v / 60 hz 2.8 180 v / 50 hz 4 230 v / 50 hz 5.7 240 v / 50 hz 6.1 265 v / 50 hz 7.5 table 3 ? no-load input power vs. input voltage including effect of mov leakage
14-apr-10 rdr-252 - capzero reference design board page 13 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8 x capacitor discharge waveforms 8.1 ac disconnect at room temperature figure 8 ? 265 vac 50 hz, no-load. v in , 100 v / div. figure 9 ? 265 vac 50 hz, no-load. v in , 100 v / div. 8.2 ac disconnect at 105 o c ambient figure 10 ? 265 vac 50 hz, no-load. v in , 100 v / div. figure 11 ? 265 vac 50 hz, no-load. v in , 100 v / div.
rdr-252 - capzero reference design board 14-apr-10 page 14 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.3 ac disconnect at -5 o c ambient figure 12 ? 265 vac 50 hz, no-load. v in , 100 v / div. figure 13 ? 265 vac 50 hz, no-load. v in , 100 v / div.
14-apr-10 rdr-252 - capzero reference design board page 15 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.4 input arcing test room temperature the ac input was connected l oosely in a manner so as to generate arcing at the contacts. the test to demonstrate that the c apzero does not stay ?l atched-off? due to the arcing event and that it proper ly detects loss of ac power and safely discharges the x capacitor once the ac is removed. figure 14 ? 265 vac 50 hz, no-load. v in , 100 v / div. figure 15 ? 265 vac 50 hz, no-load. v in , 100 v / div. figure 16 ? 265 vac 50 hz, no-load. v in , 100 v / div. figure 17 ? 265 vac 50 hz, no-load. v in , 100 v / div.
rdr-252 - capzero reference design board 14-apr-10 page 16 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com figure 18 ? 265 vac 50 hz, no-load. v in , 100 v / div. figure 19 ? 265 vac 50 hz, no-load. v in , 100 v / div.
14-apr-10 rdr-252 - capzero reference design board page 17 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.5 ac input arcing test at 105 o c ambient figure 20 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div. figure 21 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div. figure 22 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div. figure 23 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div.
rdr-252 - capzero reference design board 14-apr-10 page 18 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com figure 24 ? 265 vac 50 hz, no-load. v in zoom, 100 v / div.,20 ms / div. figure 25 ? 265 vac 50 hz, no-load. v in , 100 v / div.,200 ms / div.
14-apr-10 rdr-252 - capzero reference design board page 19 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.6 ac input arcing test at -5 o c ambient figure 26 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div. figure 27 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div. figure 28 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div. figure 29 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div.
rdr-252 - capzero reference design board 14-apr-10 page 20 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com figure 30 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div. figure 31 ? 265 vac 50 hz, no-load. v in , 100 v / div., 200 ms / div.
14-apr-10 rdr-252 - capzero reference design board page 21 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9 ac surge and ring wave test the board was tested at 230 vac with a 1 ? f capacitor and 2 x 390 k ? resistors. 9.1 ring wave test test voltage (kv) phase angle ( ? ) waveform (a) number of strikes test result 1 90 200 10 pass 1 270 200 10 pass 9.2 differential mode surge, 1.2 / 50 ? sec surge voltage (kv) phase angle ( ? ) generator impedance ( ? ) number of strikes test result 1.5 90 2 10 pass 1.5 270 2 10 pass 2 90 2 10 pass 2 270 2 10 pass 9.3 common mode surge, 1.2 / 50 ? sec surge voltage (kv) phase angle ( ? ) generator impedance ( ? ) number of strikes test result 4 90 12 10 pass 4 270 12 10 pass
rdr-252 - capzero reference design board 14-apr-10 page 22 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.4 ac disconnect test after surge proper operation of capzero was verified afte r 10 strikes of surge test and ring wave test. figure 32 ? 265 vac 50 hz, no-load. upper: v in , 100 v / div., 200 ms / div. lower: v in zoom, 100 v / div., 20 ms / div. figure 33 ? 265 vac 50 hz, no-load. upper: v in , 100 v / div., 200 ms / div. lower: v in zoom, 100 v / div., 20 ms / div.
14-apr-10 rdr-252 - capzero reference design board page 23 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 10 emi tests emi performance was tested at no-load with 1 ? f capacitors and 2 x 390 k ? resistors on the board. comparing results to backgr ounds scan it can be seen that capzero generates no measurable conducted emi. figure 34 ? 115 v neutral. figure 35 ? 115 v line. figure 36 ? 230 v neutral. figure 37 ? 230 v line.
rdr-252 - capzero reference design board 14-apr-10 page 24 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com the following emi scans are done with the uni t disconnected to show the background noise level of t he test setup. figure 38 ? 115 v neutral background noise. figure 39 ? 115 v line background noise. figure 40 ? 230 v neutral background noise. figure 41 ? 230 v line background noise.
14-apr-10 rdr-252 - capzero reference design board page 25 of 26 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11 revision history date author revision description & changes reviewed 14-apr-10 pl 0.6 initial release apps & mktg
rdr-252 - capzero reference design board 14-apr-10 page 26 of 26 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com for the latest updates, visit our website: www.powerint.com 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 fr om the use of any device or circuit described herein. power integrations makes no warranty 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 transformer construction and circuits external to the products) 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 grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. the pi logo, topswitch, tinyswitch, linkswitch, dpa-switch, peakswitch, ecosmart, clampless, e-shield, filterfuse, stackfet, pi expert and pi facts are trademarks of power integrations, inc. other trademarks are property of their respective companies. ?copyright 2010 power integrations, inc. power integrations worldwide sales support locations world headquarters 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 germany rueckertstrasse 3 d-80336, munich germany phone: +49-89-5527-3911 fax: +49-89-5527-3920 e-mail: eurosales@powerint.com japan kosei dai-3 building 2-12-11, shin-yokohama, kohoku-ku, yokohama-shi, kanagawa 222-0033 japan phone: +81-45-471-1021 fax: +81-45-471-3717 e-mail: japansales@powerint.com taiwan 5f, no. 318, nei hu rd., sec. 1 nei hu district taipei 114, taiwan r.o.c. phone: +886-2-2659-4570 fax: +886-2-2659-4550 e-mail: taiwansales@powerint.com china (shanghai) rm 1601/1610, tower 1 kerry everbright city no. 218 tianmu road west shanghai, p.r.c. 200070 phone: +86-021-6354-6323 fax: +86-021-6354-6325 e-mail : chinasales@powerint.com india #1, 14 th main road vasanthanagar bangalore-560052 india phone: +91-80-4113-8020 fax: +91-80-4113-8023 e-mail: indiasales@powerint.com korea rm 602, 6fl korea city air terminal b/d, 159-6 samsung-dong, kangnam-gu, seoul, 135-728 korea phone: +82-2-2016-6610 fax: +82-2-2016-6630 e-mail: koreasales@powerint.com united kingdom 1st floor, st. james?s house east street, farnham surrey, gu9 7tj united kingdom phone: +44 (0) 1252-730-141 fax: +44 (0) 1252-727-689 e-mail: eurosales@powerint.com china (shenzhen) rm a, b & c 4 th floor, block c, electronics science and technology building 2070 shennan zhong road shenzhen, guangdong, p.r.c. 518031 phone: +86-755-8379-3243 fax: +86-755-8379-5828 e-mail: chinasales@powerint.com italy via de amicis 2 20091 bresso mi italy phone: +39-028-928-6000 fax: +39-028-928-6009 e-mail: eurosales@powerint.com singapore 51 newton road, #15-08/10 goldhill plaza singapore, 308900 phone: +65-6358-2160 fax: +65-6358-2015 e-mail: singaporesales@powerint.com applications hotline world wide +1-408-414-9660 applications fax world wide +1-408-414-9760

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