Title
Engineering Prototype Report for EP-34 –
Single Output 30 W AC-DC Power Supply
Using TOP245Y (TOPSwitch
®
-GX)
Specification
Universal Input, 12 V at 30 W Output
Application
Author
Document
Number
Date
Revision
Features
•
•
•
•
•
Universal Input 85 VAC to 265 VAC
Low Parts Count
Zero Load Power Consumption <0.3 W at 115 VAC, <0.45 W at 230 VAC
Meets CISPR22B EMI with Margin
Efficiency >80%
Generic
Power Integrations Applications Department
EPR-34
10-Feb-04
1.1
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
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
EPR-34 – 12 V, 30 W, Universal Input
10-Feb-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 ................................................................................................................9
6 Bill Of Materials ........................................................................................................10
7 Transformer Specification.........................................................................................11
7.1
Electrical Diagram .............................................................................................11
7.2
Electrical Specifications.....................................................................................11
7.3
Materials............................................................................................................11
7.4
Transformer Build Diagram ...............................................................................12
7.5
Transformer Construction..................................................................................12
7.6
Transformer Sources.........................................................................................12
8 Transformer Spreadsheets .......................................................................................13
9 Performance Data ....................................................................................................15
9.1
Efficiency ...........................................................................................................15
9.2
No-load Input Power..........................................................................................15
9.3
Regulation .........................................................................................................16
9.3.1
Load ...........................................................................................................16
9.3.2
Line ............................................................................................................16
9.4
Overload Power.................................................................................................17
10
Thermal Performance ...........................................................................................18
11
Waveforms............................................................................................................19
11.1 Drain Voltage and Current, Normal Operation...................................................19
11.2 Output Voltage Start-up Profile..........................................................................19
11.3 Drain Voltage and Current Start-up Profile ........................................................19
11.4 Load Transient Response (75% to 100% Load Step) .......................................20
11.5 Output Ripple Measurements............................................................................21
11.5.1 Ripple Measurement Technique ................................................................21
11.5.2 Measurement Results ................................................................................22
12
Control Loop Measurements.................................................................................23
12.1 115 VAC Maximum Load...................................................................................23
12.2 230 VAC Maximum Load...................................................................................23
13
Conducted EMI .....................................................................................................24
14
AC Surge and 100 kHz Ring Wave Immunity .......................................................25
14.1 Common Mode Surge, 1.2/50
µs
.......................................................................25
14.2 Differential Mode Surge, 1.2/50
µs
....................................................................26
14.3 Common Mode, 100 kHz Ring Wave ................................................................26
14.4 Differential Mode, 100 kHz Ring Wave..............................................................26
15
Revision History ....................................................................................................27
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
1
2
3
4
Page 2 of 28
EPR-34 – 12 V, 30 W, Universal Input
10-Feb-2004
1
Introduction
This document is an engineering report describing a 12 V, 30 W universal input flyback
power supply, intended as a standard evaluation platform for
TOPSwitch-GX.
The document contains the power supply specification, schematic, bill of materials,
transformer documentation, printed circuit board layout, and performance data.
Figure 1 –
EP-34 Populated Circuit Board.
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 4 of 28
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