TOP245P_1

Design Example Report Title 32W (47W peak) Multiple Output supply using TOP245P Input: 195 - 265 VAC Specification Output: 3.3V/3A, 5V/2A (2.5A Peak), 12V/0.5A (1.5A Peak), 20V/0.3A Application Author Document Number Date Revision Set Top Box Power Integrations Applications Department DER-19 March 30, 2004 1.0 Summary and Features This report describes a design for a multiple output power supply, such as required for a Set Top Box, featuring the following: • Very high full power efficiency (> 83% at full power) • 32W Continuous power rating • 75% at 10% output power • Small DIL08 package for TOP245P requiring no external heatsink • 50W peak power capability allows for high peak output power demands (e.g. for hard disk spin-up) • Low EMI (Meets EN55022 with output ground connected to Earth) The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power Integrations, Inc. 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 Table Of Contents Introduction ................................................................................................................ 4 Power Supply Specification........................................................................................ 5 Schematic .................................................................................................................. 6 Circuit Description ...................................................................................................... 7 4.1 Input EMI Filtering............................................................................................... 7 4.2 TOPSwitch Primary............................................................................................. 7 4.3 Output Rectification............................................................................................. 7 4.4 Output Feedback ................................................................................................ 7 5 PCB Layout................................................................................................................ 8 6 Bill Of Materials .......................................................................................................... 9 7 Transformer Specification ........................................................................................ 10 7.1 Electrical Diagram............................................................................................. 10 7.2 Electrical Specifications .................................................................................... 10 7.3 Materials ........................................................................................................... 10 7.4 Transformer Build Diagram ............................................................................... 11 7.5 Transformer Construction ................................................................................. 11 8 Transformer Spreadsheets ...................................................................................... 12 9 Performance Data .................................................................................................... 15 9.1 Efficiency........................................................................................................... 15 9.2 No-load Input Power ......................................................................................... 16 9.3 Peak Power....................................................................................................... 16 9.4 Regulation......................................................................................................... 16 9.4.1 Load........................................................................................................... 16 9.4.2 Line ............................................................................................................ 17 9.5 Cross Regulation .............................................................................................. 17 10 Thermal Performance........................................................................................... 18 11 Waveforms ........................................................................................................... 18 11.1 Drain Voltage and Current, Normal Operation .................................................. 18 11.2 Output Voltage Start-up Profile (Full Power) ..................................................... 19 11.3 Drain Voltage and Current Start-up Profile ....................................................... 20 11.4 Load Transient Response ................................................................................. 20 11.5 Output Ripple Measurements ........................................................................... 21 11.5.1 Ripple Measurement Technique ................................................................ 21 11.5.2 Measurement Results ................................................................................ 22 12 Conducted EMI..................................................................................................... 24 13 Revision History.................................................................................................... 25 1 2 3 4 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 Table Of Figures Figure 1 – Populated Circuit Board (Scale in cm).............................................................. 4 Figure 2– TOP245P Schematic for 32W cont / 46W peak................................................. 6 Figure 3 – Printed Circuit Layout (Scale not 1:1) ............................................................... 8 Figure 4 –Transformer Electrical Diagram....................................................................... 10 Figure 5 – Transformer Build Diagram ............................................................................ 11 Figure 6- Full Continuous Power Conversion Efficiency.................................................. 15 Figure 7 - Efficiency Variation with Load ......................................................................... 15 Figure 8 – Load Regulation, Room Temperature, 230VAC Input...................................... 16 Figure 9 – Line Regulation, Room Temperature, Full Load............................................. 17 Figure 10 - Cross Regulation........................................................................................... 17 Figure 11 - Key Component Temperature Rise variation with Line Voltage .................... 18 Figure 12 - 195 VAC, Full Continuous Load...................................................................... 18 Figure 13 - 265 VAC, Full Continuous Load .................................................................... 18 Figure 14 -Start-up Profile, 230VAC.................................................................................. 19 Figure 15 - Start-up Profile, 230VAC................................................................................. 19 Figure 16 - Start-up Profile, 230VAC................................................................................. 19 Figure 17 - 195 VAC Input and Maximum Load. ............................................................... 20 Figure 18 - 265 VAC Input and Maximum Load............................................................... 20 Figure 19 – Transient Response, 230 VAC, 3A to 4A Step load change on 3V3. Full Load. ................................................................................................................................. 20 Figure 20 - Oscilloscope Probe Prepared for Ripple Measurement................................. 21 Figure 21 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter...................... 21 Figure 22 – 3V3 Ripple, 230 VAC, Full Load..................................................................... 22 Figure 23 – 3V3 Switching Noise, 230 VAC, Full Load. .................................................... 22 Figure 24 – 5V Ripple, 230 VAC, Full Load....................................................................... 22 Figure 25 – 5V Switching Noise, 230 VAC, Full Load. ...................................................... 22 Figure 26 – 12V Ripple, 230 VAC, Full Load..................................................................... 23 Figure 27 – 12V Switching Noise, 230 VAC, Full Load. .................................................... 23 Figure 28 – 20V Rail Ripple, 230 VAC, Full Load. ............................................................ 23 Figure 29 – 20V Rail Switching Noise, 230 VAC, Full Load. ............................................. 23 Figure 30 - Conducted EMI, Full Continuous Power, 230 VAC, and EN55022 B Limits. .. 24 Figure 31 - Conducted EMI, Full Continuous Power, 230 VAC, and EN55022 B Limits. .. 24 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 isolation transformer to provide the AC input to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built. Page 3 of 25 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 1 Introduction This engineering report describes a multiple output evaluation board designed using TOP245P. The specification chosen is targeted towards new Set Top Box systems that incorporate a hard disk. These systems require a peak power capability when the hard disk is first spun-up. Peak power operation requires magnetics and diodes specified to handle the currents at the specified peak power point. If peak power operation is not required, designing the supply for maximum continuous power will save additional cost. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and measured performance data from the prototype unit shown in Figure 1. Figure 1 – Populated Circuit Board (Scale in cm) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 2 Power Supply Specification Description Input Voltage Frequency Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Output Voltage 3 Output Ripple Voltage 3 Output Current 3 Output Voltage 4 Output Ripple Voltage 4 Output Current 4 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Safety Surge Surge Ambient Temperature TAMB Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Symbol VIN fLINE VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 POUT POUT_PEAK η Min 195 47 Typ Max 265 64 Units VAC Hz V mV A V mV A V mV Comment 2 Wire – no P.E. 50/60 3.3 ± 5% 20 MHz Bandwidth ± 5% 20 MHz Bandwidth 2.5A Peak for 10s ± 7% 20 MHz Bandwidth 1.5A Peak for 10s ± 7% 20 MHz Bandwidth 1 5 1 12 0.35 20 0.1 0.3 3 2 0.5 A V mV 0.3 31.9 46.4 A W W % 75 Measured at POUT (32 W), 25 oC 4 3 0 50 kV kV o 1.2/50 µs surge, IEC 1000-4-5, 12 Ω series impedance, differential and common mode 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level C Table 1 - Power Supply Specification Page 5 of 25 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 3 Schematic Figure 2– TOP245P Schematic for 32W cont / 46W peak Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 4 Circuit Description This power supply uses the latest generation TOPSwitch in a DIL08 package to minimize heatsink requirements. It is designed for 32W continuous operation in a 50°C ambient with magnetics designed to allow short peak power levels of up to 50W. 4.1 Input EMI Filtering Due to the frequency jittering function of TOPSwitch, the input EMI filtering is minimal, consisting of a 15mH common-mode choke and 220nF x-capacitor. Protection is provided by a 1A, 250V antisurge fuse. Inrush limiting is provided by a thermistor. Surge protection is provided by a VDR on the input. If only 4kV surge is required, this part can be removed since the TOP245P incorporates over-voltage shutdown giving additional protection. 4.2 TOPSwitch Primary On the primary side of the supply, the TOPSwitch integrates a number of functions:Frequency jitter which reduces the QP and AV EMI levels by up to 10dB Soft-Start which prevents transformer saturation during start-up. This increases long term reliability Line UV and OV detection to give additional differential surge withstand capability Regulation to zero load without pre-load due to very low minimum duty cycle capability Line feed forward which improves 100Hz ripple rejection Hysteretic thermal and short circuit protection to increase long term reliability A 47uF input capacitor has been used to provide the high peak power capability. If peak power operation is not required, this can be reduced to 33uF, 400V which will save further cost. 4.3 Output Rectification A fully AC stacked design has been used to give good cross-regulation. A snubber is placed across D7 to reduce high frequency common-mode EMI emissions. Post filters are used on all outputs to meet noise and ripple requirements. 4.4 Output Feedback Full PWM feedback has been implemented using a TL431 reference and opto-coupler. Feedback is split over the 3V3 and 5V rails, each giving equal influence to the feedback network. D10, R10 and C11 provide a soft-finish function, ensuring a monotonic rise in the output voltages with zero overshoot. Page 7 of 25 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 5 PCB Layout The evaluation board was implemented using a single copper layer. Figure 3 shows the component placement and underside copper routing. Figure 3 – Printed Circuit Layout (Scale not 1:1) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 6 Bill Of Materials Reference R1,R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 C1 C2 C3,C12 C4 C5 C6 C7 C8,C9 C10 C11 C13 C14 C15 C16 C17 C18 U1 U2 U3 D1,D2,D3,D4 D5 D6 D7,D8 D9 D10 D11 D12 FU1 T1 L2 L7,L8,L9 VDR1 Quantity 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 4 1 1 2 1 1 1 1 1 1 1 3 1 Total of 52 components Value 1M 6R8 3k3 10k, 1% 22k, 1% 6k8, 1% 150R 1k 10k 20R, 2W NTC 3R3 220nF, X2 CAP 47uF, 400V 100nF 47uF, 10V 1000uF, 35V 470uF, 35V 100uF, 35V 100uF, 10V 47uF, 16V 22uF, 10V 2.2nF, Y1_CLASS 1uF, 50V 39uF, 35V 47uF, 35V 1nF, 1kV 4.7nF TL431 PC817 TOP245P 1N4007 1N4937 P4KE200 MBR1035 SR506 BAS19 IN4148 UF4002 1A, 250V EF30 Custom Transformer 4.7uH, 1A 4.7uH, 3.2A 300V Page 9 of 25 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 7 Transformer Specification 7.1 Electrical Diagram Figure 4 –Transformer Electrical Diagram 7.2 Electrical Specifications 1 second, 60 Hz, from Pins 1-4 to Pins 7-12 Pins 1-4, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-4, all other windings open Pins 1-4, with Pins 7-8 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 1180 µH, 0/+20% 600 kHz (Min.) 50 µH (Max.) Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 Materials Description 2 Core: EF30 CORE, 3C85, Gapped for 234nH/T (Approximately 0.28mm) Bobbin: EF30, 10 pin Magnet Wire: 0.24mm Diameter Heavy Nyleze Copper Foil: See section below Tape: 16mm wide insulation tape Tape: 3mm margin tape Magnet Wire: 0.45mm Diameter Heavy Nyleze Varnish Item [1] [2] [3] [4] [5] [6] [7] [8] Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 7.4 Transformer Build Diagram 1 2 ½ Primary 12 12V & 20V 11 Secondaries 9 7,8 10 5V Secondary 3V3 Secondary Bias ½ Primary 3mm Margin Tape Figure 5 – Transformer Build Diagram 3 2 6 4 7mm 10mm 0.2mm Thick Copper Foil Insulation Tape 7.5 Transformer Construction Bobbin Preparation ½ Primary Basic Insulation Bifilar Bias Winding Insulation 3V3 and 5V Windings 12V and 20V Windings ½ Primary Outer Wrap Final Assembly Place 3mm of Margin tape on each side of the EF30 Bobbin Start at Pin 4. Wind 36 turns of item [3] in approximately 1 layer. Bring finish lead back to start. Finish on Pin 2. Use two layers of item [5] for basic insulation. Starting at Pin 6, wind 9 bifilar turns of item [3]. Spread turns evenly across bobbin. Finish at Pin 3. Use three layers of item [5] for safety insulation. Start at Pins 7 and 8. Wind 2 turns of copper foil [4]. Bring termination wire out onto pin 9. Continue with one further copper foil turn and finish with termination on pin 10. Start at Pin 10. Wind 4 turns of 4 parallel strands of item [7] using half the bobbin width. Terminate on pin 11. Continue with 4 further turns of 4 parallel strands of item [7] using the remaining half bobbin width. Finish on pin 12. Start at Pin 2. Wind 35 turns of item [3] in approximately 1 layer. Bring finish lead back to start. Finish on Pin 1. W rap windings with 3 layers of tape item [5]. Assemble and secure core halves. Varnish impregnate (item [8]). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 11 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 8 Transformer Spreadsheets This design was produced using PIExpert assuming a TOP245P device with a current limit capability of 1.1A and an Rdson of 4Ω. The data below reflects the full continuous load, which gives approximately 0.7A peak primary current. The transformer has been designed to operate with safe flux levels with primary currents of up to 1.2A allowing for the peak power capability. Power Supply Input VACMIN VACMAX FL TC Volts Volts Hertz mSeconds 195 265 50 1.81 Min Input AC Voltage Max Input AC Voltage AC Main Frequency Bridge Rectifier Conduction Time Estimate Loss Allocation Factor Efficiency Estimate Z N % 0.68 74.0 Power Supply Outputs VOx IOx VB IB Volts Amps Volts Amps 3.30 3.000 15.00 0.006 5.00 2.000 12.00 20.00 Output Voltage 0.500 0.300 Output Current Bias Voltage Bias Current Device Variables Device PO VDRAIN Watts Volts TOP245P 31.99 678 Device Name Total Output Power Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Device Switching Frequency Ripple to Peak Current Ratio External Current Limit Ratio Peak Primary Current Primary RMS Current Maximum Duty Cycle FS KRPKDP KI IP IRMS DMAX Hertz 132000 0.70 1.00 Amps Amps 0.75 0.31 0.36 Power Supply Components Selection CIN uFarads 47.0 Input Filter Capacitor Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 25 DER-19 VMIN VMAX VCLO PZ VDB PIVB Volts Volts Volts Watts Volts Volts TOP245P Multiple Output Set Top Box 247 375 200 2.0 0.7 59 March 30, 2004 Minimum DC Input Voltage Maximum DC Input Voltage Clamp Zener Voltage Bias Winding Diode Forward Voltage Drop Bias Rectifier Maximum Peak Inverse Voltage Power Supply Output Parameters VDx PIVSx Volts Volts 0.5 14 0.5 20 0.7 47 0.7 Output Winding Diode Forward Voltage Drop 77 Output Rectifier Maximum Peak Inverse Voltage 0.77 Peak Secondary Current 0.42 Secondary RMS Current 0.30 Output Capacitor RMS Ripple Current ISPx ISRMSx IRIPPLEx Amps Amps Amps 7.74 4.22 2.96 5.16 2.81 1.97 1.29 0.70 0.49 Transformer Construction Parameters Core/Bobbin Core Manuf. Bobbin Manuf LP NP NB OD Actual Primary Current Density VOR BW M L mm A/mm^2 E30/15/7 Margin Generic Generic 1181 71 8.26 0.25 6 Core and Bobbin Type Core Manufacturing Bobbin Manufacturing Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns Primary Actual Wire Diameter Primary Winding Current Density Reflected Output Voltage Bobbin Physical Winding Width Safety Margin Width Number of Primary Layers Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com uHenries Volts mm mm 135.00 17.30 3.0 2.0 Page 13 of 25 DER-19 AE ALG BM BP BAC LG LL cm^2 nH/T^2 mTesla mTesla mTesla mm uHenries TOP245P Multiple Output Set Top Box 0.60 234 207 267 73 0.28 17.7 March 30, 2004 LSEC nHenries 20 Core Effective Cross Section Area Gapped Core Effective Inductance Maximum Operating Flux Density Peak Flux Density AC Flux Density for Core Curves Gap Length Estimated Transformer Primary Leakage Inductance Estimated Secondary Trace Inductance Secondary Parameters NSx Rounded Down NSx 2.00 2.89 2 6.68 10.89 Secondary Number of Turns 6 10 Rounded to Integer Secondary Number of Turns 10.62 18.17 Auxiliary Output Voltage for Rounded to Integer NSx 7 11 Rounded to Next Integer Secondary Number of Turns 12.51 20.05 Auxiliary Output Voltage for Rounded to Next Integer NSx 0.25 - 0.20 - Secondary Actual Wire 0.40 0.32 Diameter Range Comment: Wire diameter is greater than recommended maximum (0.40 mm) and may overheat. Tip: Consider a parallel winding technique (bifilar, trifilar), increase size of transformer (larger BW), reduce margin (M). Rounded Down Vox Volts 3.27 Rounded Up NSx 3 Rounded Up Vox ODS Actual Range Volts 5.16 mm 0.64 1.03 0.51 0.81 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 9 Performance Data All measurements performed at room temperature, 50 Hz input frequency. 9.1 Efficiency Full power efficiency was measured as a function of line voltage and Figure 6 gives the resulting profile. 90 88 86 Efficiency (%) 84 82 80 78 76 74 72 70 180 200 220 240 260 280 Line Voltage (VRMS) Figure 6- Full Continuous Power Conversion Efficiency Efficiency as a function of output power was measured at 230V input, each rail load increased from zero to 100% load simultaneously in 10% load steps. Figure 7 shows the resulting efficiency profile. 90 80 70 Efficiency (%) 60 50 40 30 20 10 0 0 5 10 15 20 25 30 35 Output Power (W) Figure 7 - Efficiency Variation with Load Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 15 of 25 DER-19 9.2 TOP245P Multiple Output Set Top Box March 30, 2004 No-load Input Power Under zero output load conditions, the input power was measured at 400mW at 265VAC input. 9.3 Peak Power The prototype was loaded to the specified peak power levels in Table 1 and the temperature of the TOP245P monitored. The 46W peak power level can easily be supplied in 25°C ambient conditions. Under peak power levels, the TOP245P temperature was measured at 86°C. Thus, a peak power of 46W in 50°C ambient is achievable and only thermal shutdown will limit the time the peak power can be delivered for. With the high operating efficiency of this design, peak power levels of above 50W can be achieved for a few seconds. 9.4 Regulation 9.4.1 Load Regulation (% of nominal voltage) 25 20 15 10 5 0 -5 0 5 10 15 20 25 30 35 Output Power (W) 3V3 5V 12V 20V Figure 8 – Load Regulation, Room Temperature, 230VAC Input Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 9.4.2 Line Line regulation was measured at full continuous output power. The regulation, expressed as a percentage on nominal rail voltage, and as a function of line voltage is shown in Figure 9 below. 10 8 6 4 2 0 -2 -4 -6 -8 -10 180 Regulation (% relative to nominal) 3V3 5V 12V 20V 200 220 240 260 280 Line Voltage (Vrms) Figure 9 – Line Regulation, Room Temperature, Full Load. 9.5 Cross Regulation Figure 10 gives the cross regulation results at 230V input. 3V3 - 5V - 12V - 20V XXXX XXXM XXMX XXMM XMXX XMXM XMMX XMMM MXXX MXXM MXMX MXMM MMXX MMXM MMMX MMMM Min (V) Max (V) % Below % Above Min Load (X) Max Load (M) 3V3 3.38 3.39 3.38 3.39 3.40 3.39 3.39 3.33 3.33 3.28 3.30 3.27 3.25 3.24 3.24 3.22 3.22 3.40 -2.42 3.03 1 3 5V 5.28 5.28 5.28 5.00 5.19 5.18 5.19 5.10 5.25 5.20 5.17 5.10 5.15 5.12 5.14 5.12 5.00 5.28 0.00 5.60 1 2 12V 12.70 12.67 12.63 12.62 12.94 12.79 12.77 12.55 13.19 12.87 12.92 12.72 13.00 12.80 12.83 12.69 12.55 13.19 4.58 9.92 0.35 0.5 20V 19.95 19.63 19.92 19.64 20.53 19.86 20.30 19.58 20.85 20.00 20.57 19.80 20.76 19.93 20.79 19.84 19.58 20.85 -2.10 4.25 0.1 0.3 Figure 10 - Cross Regulation Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 17 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 10 Thermal Performance At full continuous output power, the temperature of key components was monitored using thermocouples. In a 25°C ambient, Figure 11 gives the resulting temperature profiles. 100 90 Temperature (Deg C) 80 70 60 50 40 30 20 10 0 180 200 220 240 260 280 TOP245P Transformer 3V3 Diode 5V Diode Ambient Line Voltage (Vrms) Figure 11 - Key Component Temperature Rise variation with Line Voltage All key components are operating well within specified temperature ranges and this design would support operation in ambient levels up to 50°C. 11 Waveforms 11.1 Drain Voltage and Current, Normal Operation Figure 12 - 195 VAC, Full Continuous Load Lower: IDRAIN, 0.5 A / div Upper: VDRAIN, 200 V, 2 µs / div Figure 13 - 265 VAC, Full Continuous Load Lower: IDRAIN, 0.5 A / div Upper: VDRAIN, 200 V / div Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 11.2 Output Voltage Start-up Profile (Full Power) Figure 14 -Start-up Profile, 230VAC Lower: 3V3, 1 V / div Upper: 5V, 2 V / div Figure 15 - Start-up Profile, 230VAC Lower: 3V3, 1 V / div Upper: 12V, 5 V / div Figure 16 - Start-up Profile, 230VAC Lower: 3V3, 1 V / div Upper: 20V, 10 V / div Page 19 of 25 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 11.3 Drain Voltage and Current Start-up Profile Figure 17 - 195 VAC Input and Maximum Load. Lower: IDRAIN, 0.5 A / div. Upper: VDRAIN, 200 V & 1 ms / div. Figure 18 - 265 VAC Input and Maximum Load. Lower: IDRAIN, 0.5 A / div. Upper: VDRAIN, 200 V & 1 ms / div. 11.4 Load Transient Response Figure 19 shows the load transient response of the 3V3 rail when subjected to a load change for 3A to 4A. Figure 19 – Transient Response, 230 VAC, 3A to 4A Step load change on 3V3. Full Load. Lower – Current at 2A / div, Upper – AC coupled 3V3 voltage at 50mV / div Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 11.5 Output Ripple Measurements 11.5.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 20 and Figure 21. 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). Probe Ground Probe Tip Figure 20 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 21 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added) Page 21 of 25 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 11.5.2 Measurement Results Figure 22 – 3V3 Ripple, 230 VAC, Full Load. 2 ms / div, 20 mV / div Figure 23 – 3V3 Switching Noise, 230 VAC, Full Load. 5us / div, 5 mV / div Figure 24 – 5V Ripple, 230 VAC, Full Load. 2 ms / div, 20 mV / div Figure 25 – 5V Switching Noise, 230 VAC, Full Load. 5 us / div, 5 mV / div Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 Figure 26 – 12V Ripple, 230 VAC, Full Load. 2 ms / div, 20 mV / div Figure 27 – 12V Switching Noise, 230 VAC, Full Load. 5us / div, 5 mV / div Figure 28 – 20V Rail Ripple, 230 VAC, Full Load. 2 ms / div, 20 mV / div Figure 29 – 20V Rail Switching Noise, 230 VAC, Full Load. 5us / div, 20 mV / div Page 23 of 25 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 12 Conducted EMI Figure 30 - Conducted EMI, Full Continuous Power, 230 VAC, and EN55022 B Limits. Output ground connected to protective earth. Worst case live/neutral measurement. Figure 31 - Conducted EMI, Full Continuous Power, 230 VAC, and EN55022 B Limits. Output ground floating. Worst case live/neutral measurement. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 25 DER-19 TOP245P Multiple Output Set Top Box March 30, 2004 13 Revision History Date Author March 30, 2004 IM Revision 1.0 Description & changes First Draft Released Reviewed VC / AM For the latest updates, visit our Web site: 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 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 CHINA Power Integrations International Holdings, Inc. Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu Shenzhen Guangdong, 518031 Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 EUROPE & AFRICA Power Integrations (Europe) Ltd. Centennial Court Easthampstead Road Bracknell Berkshire RG12 1YQ, United Kingdom Phone: +44-1344-462-300 Fax: +44-1344-311-732 e-mail: eurosales@powerint.com KOREA Power Integrations International Holdings, Inc. 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