Power Integrations EP-93 User Manual

Engineering Prototype Report for EP-93 –

Title

32 W/81 W Peak
PeakSwitch

™

Supply Using

(PKS606Y)

90-265 VAC Input, 30 V, 1.07 A (continuous),

Specification

2 A (100 ms), 2.7 A (50 ms) Output

Application Printers, DVRs, Audio, General Purpose
Author Power Integrations Applications Department
Document

EPR-93

Number
Date

22-Jun-2006

Revision 1.4

Summary and Features

• EcoSmart® – meets all existing and proposed harmonized energy efficiency

standards including: CECP (China), CEC, EPA, AGO, European Commission

• No-load power consumption 200 mW at 265 VAC

• 81.8% active-mode efficiency (exceeds requirement of 80.2%)

• Tight tolerance I

• Increases MOSFET and magnetics power delivery

• Reduces worst-case overload power, which lowers component costs

• Allows small EE25 core size

• Integrated PeakSwitch safety/reliability features:

• Accurate (± 5%), auto-recovering, hysteretic thermal shutdown function

maintains safe PCB temperatures under all conditions

• Auto-restart protects against output short circuits and open feedback loops

• Adaptive current limit reduces output overload power

• Programmable smart AC line sensing provides latching shutdown during

short circuit, overload and open loop faults and prevents power ON/OFF
glitches during power down or brownout

• Meets EN55022 and CISPR-22 Class B conducted EMI with >14 dBµV margin

• Meets IEC61000-4-5 Class 3 AC line surge

2

f parameter (-10%/+12%) reduces system cost:

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

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’ pate nts may be found at
www.powerint.com.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

Table Of Contents

1 Introduction.................................................................................................................5

2 Power Supply Specification ........................................................................................6

3 Schematic...................................................................................................................7

4 Circuit Description.......................................................................................................8

4.1 Input EMI Filtering................................................................................................8

4.2 PeakSwitch Primary.............................................................................................8

4.3 Output Rectification and Filtering .........................................................................9

4.4 Output Feedback.................................................................................................9

4.5 Output Protection.................................................................................................9

5 PCB Layout...............................................................................................................10

6 Bill Of Materials.........................................................................................................11

7 Transformer Specification.........................................................................................13

7.1 Electrical Diagram..............................................................................................13

7.2 Electrical Specifications.....................................................................................13

7.3 Materials............................................................................................................14

7.4 Transformer Build Diagram................................................................................14

7.5 Transformer Construction..................................................................................15

8 Transformer Spreadsheet.........................................................................................16

9 Performance Data.....................................................................................................19

9.1 Efficiency...........................................................................................................19

9.1.1 Active Mode CEC Measurement Data........................................................19

9.2 No-load Input Power..........................................................................................21

9.3 Available Standby Output Power.......................................................................21

9.4 Regulation .........................................................................................................22

9.4.1 Load Regulation .........................................................................................22

9.4.2 Line Regulation...........................................................................................22

10 Thermal Performance............................................................................................23

11 Waveforms............................................................................................................24

11.1 Drain Voltage and Current, Normal Operation...................................................24

11.2 Output Voltage Start-up Profile..........................................................................24

11.3 Drain Voltage and Current Start-up Profile........................................................25

11.4 Load Transient Response (1 A to 2 A Load Step).............................................25

11.5 Holdup Time......................................................................................................26

11.6 AC Line Disturbance..........................................................................................27

12 Output Ripple Measurements................................................................................30

12.1.1 Ripple Measurement Technique.................................................................30

12.1.2 Measurement Results.................................................................................31

13 Output Over-current Shutdown/Restart.................................................................32

14 Line Surge.............................................................................................................33

15 Conducted EMI .....................................................................................................34

16 Appendix...............................................................................................................36

16.1 Heat Sink Drawing.............................................................................................36

17 Revision History ....................................................................................................37

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

Important Note:

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.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

1 Introduction

This document is an engineering report describing a 90-265 VAC input, 30 V, 1.07 A
continuous, 2.7 A peak output power supply utilizing a PKS606Y. This power supply is
intended as a general-purpose evaluation platform for PeakSwitch, and is ideal for
applications where a significant pulsed output load is required, such as printers, audio
amplifiers, DVRs and DC motor drives.

The document contains the power supply specification, schematic, bill of materials,
transformer documentation, printed circuit layout, and performance data.

Figure 1 – EP-93 Populated Circuit Board Photograph.

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

2 Power Supply Specification

Description Symbol Min Typ Max Units Comment

Input

Voltage
Frequency
No-Load Input Power (230 VAC) 0.2 W

Output

Output Voltage
Output Ripple Voltage
Output Current

Total Output Power

Continuous Output Power
Peak Output Power

Efficiency

Full Load
Required average efficiency at

25, 50, 75 and 100 % of P

OUT

Environmental

Conducted EMI
Safety

Surge

Surge
Ambient Temperature

V

f

IN

LINE

90 265 VAC
47 50/60 64 Hz

2 Wire – no P.E.

27 30 33 V

V

OUT1

V

RIPPLE1

I

OUT1

400 mV

0 1.07 2.71 A

20 MHz bandwidth

P

OUT

P

OUT_PEAK

32 W
81 W

η

η

CEC

82 %

80.2

%

Measured at P

Per California Energy Commission

(CEC) / ENERGY STAR

requirements

Meets CISPR22B / EN55022B

T

AMB

Designed to meet IEC950, UL1950

1 (D)
2 (C)

1 (D)
2 (C)

0 50

kV

kV

Class II

1.2/50 µs surge, IEC 1000-4-5,
Series Impedance:

Differential Mode (D): 2 Ω
Common Mode (C): 12 Ω

100 kHz ring wave, 500 A short

circuit current, differential (D) and

o

C

common mode (C)

Free convection, sea level

± 10%

OUT,

25

o

C

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

3 Schematic

Page 7 of 40

Figure 2 – EP-93 Schematic.

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

4 Circuit Description

4.1 Input EMI Filtering

Components C1, C2, C3, C10, C17, C19, R15, L1, and L2 provide common mode and
differential mode EMI filtering. The use of two Y capacitors (C10 and C19) together with
an output common choke (L2) and the frequency jitter feature of PeakSwitch allows the
supply to meet EN55022B conducted EMI limits even with the output connected directly
to safety earth ground. On the PCB layout C19 is placed so that the primary side is
connected as close to the bulk capacitor as possible to route surge currents away from
U1. Resistors R1 and R2 discharge C3 when AC power is removed.

4.2 PeakSwitch Primary

Components D5, C7, and R5, R6 provide AC line and under voltage sensing for
PeakSwitch U1. At startup, switching is inhibited until the input voltage is above the
under-voltage threshold, determined when a current >25 µA flows into the EN/UV pin.
Once the threshold is exceeded, the under-voltage status is not checked until auto-restart
is triggered (no feedback for 30 ms). This allows the supply to continue to operate even
below the under-voltage threshold as long as the output remains in regulation,
maximizing hold-up time.

The separate AC sense network of D5 and C7 allows the PeakSwitch to determine the
cause of loss of regulation. If the input voltage is above the under-voltage threshold, then
a fault condition is assumed. In this case PeakSwitch will latch off. If the input voltage is
below the under-voltage threshold then loss of regulation was due to a low line condition
and PeakSwitch will stop switching (but not latch off) until the under-voltage threshold is
exceeded again.

Once latched off, the supply can be reset by removing the AC input such that C7
discharges and the current into the EN/UV pin falls below 25 µA. The under-voltage
function can be disabled by removing R6. Resistor R16 provides a small amount of bias
to the U1 EN/UV pin to keep the under-voltage lockout function activated during brownout
conditions when C7 may discharge.

Diode D7, C6, C8, and R7 provide bias power and decoupling to U1.
Diode D6, C5, R3, R4, and VR1 clamp the U1 drain voltage to safe levels. Use of a

moderately slow diode (t

≤ 500 ns) for D6 increases power supply efficiency.

RR

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

4.3 Output Rectification and Filtering

The secondary of the transformer is rectified and filtered by D8 and C12. As the peak
load condition is of short duration, the output capacitor ripple current rating is appropriate
for the continuous output current. As capacitor lifetime is a function of temperature rise,
this can be used to determine if the capacitor rating (ESR and ripple current specification)
is acceptable. Resistor R8 and capacitor C11 are fitted to reduce high frequency EMI.

4.4 Output Feedback

Diodes D9 and VR2, along with the forward drop of the LED of optocoupler U2, set the
output voltage of the power supply. Resistor R13 provides a bias current through D9 and
VR2 to improve regulation by operating VR2 closer to its knee and test current. Resistor
R12 sets the overall gain of the feedback loop while capacitor C15 boosts high frequency
loop gain to reduce pulse grouping. A high gain (300-600%) optocoupler U2 is used to
reduce control loop delays.

4.5 Output Protection

Components Q1, Q2, R9 to R11, R14, C13, C16, D10, and VR3 are used for latching
overvoltage and overcurrent protection in conjunction with the smart AC sensing feature,
to shut down the supply in a fault condition. If either an output overvoltage (e.g. opto­coupler failure), or overcurrent (e.g. motor stall) fault occurs, SCR Q2 is fired, shorting the
output winding. The SCR is connected directly to the secondary winding to allow a lower
current rating and lower cost device to be used, as the SCR does not have to discharge
the output capacitor.

The value of VR3 is selected to give the desired overvoltage trigger threshold. For
overcurrent protection, the value of R9 is selected to turn on Q1 at the desired
overcurrent threshold while R10 and C13 provide a time constant, to prevent short
duration (~200 ms) transient loads from triggering shutdown.

The shutdown condition can be reset by briefly removing AC power for ~3 seconds
(maximum), the time required for C7 to discharge and the current into the EN/UV pin to
fall below 25 µA.

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

5 PCB Layout

Figure 3 – EP-93 Printed Circuit Layout.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

6 Bill of Materials

Item Qty Part Ref Description Mfg Part Number Mfg

1 2 C1 C2 100 pF, Ceramic, Y1 ECK-DNA101MB Panasonic
2 1 C3 680 nF, 275 VAC, Film, X2 PX684K3ID6 Carli
3 1 C4

4 1 C5 2.2 nF, 1 kV, Disc Ceramic 5GAD22 Vishay
5 1 C6

6 1 C7 100 nF, 400 V, Film ECQ-E4104KF Panasonic
7 2 C8 C14 220 nF, 50 V, Ceramic, Z5U, 0.2" L.S. C322C224M5U5CA Kemet
8 2 C10 C19 1 nF, Ceramic, Y1 ECK-DNA102MB Panasonic
9 1 C11 330 pF, 1 kV, Disc Ceramic 5GAT33 Vishay
10 1 C12

11 1 C13 47 uF, 16 V, Electrolytic, Gen Purpose,
12 2 C15 C16 100 nF, 50 V, Ceramic, Z5U C317C104M5U5CA Kemet

150 µF, 400 V, Electrolytic,
(18 x 35.5)

47 µF, 35 V, Electrolytic,
Gen Purpose, (5 x 11)

330 µF, 50 V, 22 mΩ, Electrolytic,
(10 x 25)

(5 x 11.5)

YSD2GM151L32B0
BAI0264

ECA-1VHG470 Panasonic

EEU-FM1H331L Panasonic
ECA-1CHG470 Panasonic

Luminous Town

13 1 C17 4700 pF, 1 kV, Thru-hole, Disc Ceramic 5GAD47 Vishay/Sprague
14 5 D1 D2 D3

D4 D5

15 1 D6 800 V, 1 A, Fast Recovery Diod e, 500 ns,
16 2 D7 D9 75 V, 300 mA, Fast Switching, DO-35 1N4148 Vishay

17 1 D8 150 V, 3 A, Schottky, DO-201AD STPS3150RL ST
18 1 D10 200 V, 1 A, Ultrafast Recovery, 50 ns,

19 1 F1 3.15 A, 250 V, Slow, TR5 3,821,315,0410 Wickman
20 1 HS1 HEATSINK/Alum, TO-220 1-hole, 2 Mtg

21 1 J1 AC Input Receptacle and Accessory Plug,
22 1 J2 2 Position (1 x 2) header, 0.156-pitch,
23 1 J3 PCB Terminal Hole, 18 AWG N/A N/A

24 1 JP1 Wire Jumper, Non-insulated, 22 AWG,
25 1 JP2 Wire Jumper, Non-insulated, 22 AWG,
26 1 L1 5.3 mH, 1 A, Common Mode Choke ELF15N010A Panasonic

27 1 L2
28 1 U1 (REF) Nut, Hex, Kep 4-40, Zinc Plate
29 1 Q1 PNP, Small Signal BJT, 40 V, 0.2 A, TO-

30 1 Q2 SCR, 400 V, 1.25 A, TO-92 FS0202DA Fagor
31 2 R1 R2
32 1 R3
33 1 R4

1000 V, 1 A, Rectifier, DO-41 1N4007 Vishay

FR106 Diodes Inc.

DO-41

UF4003 Vishay

DO-41

Custom Clark Precision

Pins
PCBM
Vertical

0.4 in

0.3 in

5.3 µH, 4 A, Common Mode Choke Bead

92

1.3 MΩ, 5%, 1/4 W, Carbon Film
10 kΩ, 5%, 1/2 W, Carbon Film
22 Ω, 5%, 1/2 W, Carbon Film

161-R301SN13 Kobiconn
26-48-1021 Molex

298 Alpha
298 Alpha

Custom

2N3906 Vishay

CFR-25JB-1M3 Yageo
CFR-50JB-10K Yageo
CFR-50JB-22R Yageo

Sheetmetal

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

34 1 R5
35 1 R6
36 1 R7
37 1 R8
38 1 R9
39 1 R10
40 1 R11
41 2 R12 R13
42 1 R14
43 1 R15
44 1 R16
45 1 RT1
46 1 U1 (REF) SCR, Phillips, 4-40 X 5/16 Pan-head

47 1 T1 Transformer, EE25, 10 Pins, Vertical SIL6039

48 1 U1 PeakSwitch, PKS606Y, TO-220-7C PKS606Y Power
49 1 U2 Optocoupler, 35 V, CTR 300-600%, 4-DIP PC817X4 Sharp

50 1 VR1 100 V, 5%, 1 W, DO-41 1N4764A Microsemi
51 1 VR2 28 V, 5%, 500 mW, DO-35 1N5255B Microsemi
52 1 VR3 36 V, 5%, 500 mW, DO-35 1N5258B Microsemi
53 1 U1 (REF) Washer Flat #4, Zinc Plated #4FWZ Building

54 1 PCB, EP-93, REVD
55 1 J1 (REF) Wire, UL1015, 18 AWG, GRN/YEL 8918-189 Belden
56 1 J1 (REF) Heat Shrink, 1/4-inch, BLK 221014-6BK Alpha
57 1 J1 (REF) Snap-in Terminal 02-07-2102 Molex
58 1 U1 (REF) Silicone Heat Sink Compound
59 1 C4, RT1, L2

(REF)

2.2 MΩ, 5%, 1/4 W, Carbon Film

2.4 MΩ, 5%, 1/4 W, Carbon Film

4.7 kΩ, 5%, 1/4 W, Carbon Film
68 Ω, 5%, 1/2 W, Carbon Film

0.33 Ω, 5%, 2 W, Metal Oxide

1.5 kΩ, 5%, 1/8 W, Carbon Film
3 kΩ, 5%, 1/4 W, Carbon Film
1 kΩ, 5%, 1/4 W, Carbon Film
100 Ω, 5%, 1/8 W, Carbon Film

2.2 Ω, 5%, 1/8 W, Carbon Film

2.7 MΩ, 5%, 1/8 W, Carbon Film
NTC Thermistor, 10 Ω, 1.7 A

Machine Screw, Steel, Zinc Plate

Silicone Adhesive, Non-corrosive 19-155 GC Electronics

CFR-25JB-2M2 Yageo
CFR-25JB-2M4 Yageo
CFR-25JB-4K7 Yageo
CFR-50JB-68R Yageo
RS2 0.33 5% A Stackpole/Sei
CFR-12JB-1K5 Yageo
CFR-25JB-3K0 Yageo
CFR-25JB-1K0 Yageo
CFR-12JB-91R Yageo
CFR-12JB-2R2 Yageo
CFR-12JB-2M7 Yageo
CL-120 Thermometrics

Hi Cal
LSPA10545
SNX1882

LiShin

Santronics

Integrations

Fasteners

Note: (REF) indicates mechanical items associated with the referenced component(s) but
that are not shown on the schematic.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

7 Transformer Specification

7.1 Electrical Diagram

NC

WDG #4
7T
2 X 29 AWG

WDG #5
19T
2 X 29 AWG

WDG #1
20T
2 X 29 AWG

2

WDG #2
5T
2 X 29 AWG

4

WDG #3
10T
4 X 26 AWG Triple insulated

9,10

7,8

Figure 4 – Transformer Electrical Diagram.

7.2 Electrical Specifications

Electrical Strength 1 Second, from Pins 1-5 to

Pins 6-10

Creepage Between Pins 1-5 and Pins 6-10 6 mm (Min.)

Primary Inductance Pins 1-2, All other Windings Open,

Measured at 100 kHz, 0.4 VRMS

Resonant Frequency Pins 1-2, All other Windings Open 2 MHz

Primary Leakage

Inductance

Pins 1-2, with Pins 6-10 Shorted,
Measured at 100 kHz, 0.4V RMS

3000 VAC,

60 Hz

132 µH,

±10%
(Min.)

5.5 µH
(Max.)

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

5

3

7.3 Materials

Item Description

[1]

Core: (EE25) E25/10/6 Ferroxcube 3C90 Material or Equivalent
Gapped for AL of 88 nH/T2

[2]

Bobbin: 10-pin EE25, Vertical Mount, Yih Hwa YW-360 or
Equivalent

[3]
[4]
[5]
[6]

Magnet Wire: #29 AWG Double-coated
Triple Insulated Wire: #26 AWG
Tape, 3M #1298 or Equivalent 10.8 mm Wide
Varnish

7.4 Transformer Build Diagram

Pins Side

1

½ Primary

1

Tape

7,8

9,10

4

3
2

Secondary

Bias

½ Primary

Figure 5 – Transformer Build Diagram.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

7.5 Transformer Construction

1/2 Primary Start at Pin 2. Wind 20 bifilar turns of item [3] in

approximately 1.25 layer, finish on Pin 3.

Basic Insulation Use one layer of item [5] for basic insulation.

Bifilar Bias

Winding

Starting at Pin 5, wind 5 bifilar turns of item [3]. Spread turns
evenly across bobbin. Finish at Pin 4.

Basic Insulation Use two layers of item [5] for basic insulation.

30 V Quad filar

Secondary

Winding

Start at Pins 9 and 10. Wind 10 quad filar turns of item [4]
(about 2 layers). Spread turns evenly across bobbin. Finish
on Pins 7 and 8.

Basic Insulation Use two layers of item [5] for basic insulation.

Shield Starting at Pin 1, wind 7 bifilar turns of item [3]. Spread turns

evenly across bobbin. Leave 1/2-inch of flying lead at finish.

Basic Insulation Use two layers of item [5] for basic insulation. Trap flying lead

from shield winding between tape layers.

1/2 Primary Start at Pin 3. Wind 19 bifilar turns of item [3] in

approximately 1 layer, finish on Pin 1.

Finish Wrap Use three layers of item [5] for finish wrap.

Final Assembly Assemble and secure core halves. Dip Varnish (item [6]).

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

8 Transformer Spreadsheet

ACDC_PeakSwitch_0

31006; Rev.1.1;

©Copyright Power

Integrations 2006

ENTER APPLICATION VARIABLES

VACMIN 90 Volts Minimum AC Input Voltage
VACMAX 265 Volts Maximum AC Input Voltage
fL 50 Hertz AC Mains Frequency
Nominal Output
Voltage (VO)
Maximum Output
Current (IO)
Minimum Output
Voltage at Peak Load
Continuous Power 32.00
Peak Power
n 0.75 Efficiency Estimate at output terminals and at peak load.

Z 0.60 Loss Allocation Factor (Z = Secondary side losses / Total losses)
tC Estimate 3.00 mSeconds Bridge Rectifier Conduction Time Estimate
CIN 150.00 150 uFarads Input Capacitance

ENTER PeakSwitch VARIABLES

PeakSwitch PKS606Y PKS606Y PeakSwitch device

Chosen Device

ILIMITMIN 2.600 Amps Minimum Current Limit
ILIMITMAX 3.000 Amps Maximum Current Limit
fSmin 250000 Hertz Minimum Device Switching Frequency
I^2fmin 1955 A^2kHz I^2f (product of current limit squared and frequency is trimmed for

VOR 120.00 120 Volts Reflected Output Voltage (VOR <= 135 V Recommended)
VDS 8.00 8 Volts PeakSwitch on-state Drain to Source Voltage
VD 1.00 1 Volts Output Winding Diode Forward Voltage Drop
VDB 0.7 Volts Bias Winding Diode Forward Voltage Drop
VCLO 170
KP (STEADY STATE) 0.50 Ripple to Peak Current Ratio (KP < 6)
KP (TRANSIENT) 0.30 Ripple to Peak Current Ratio under worst case at peak load

ENTER UVLO VARIABLES

V_UV_TARGET 89 Volts Target DC under-voltage threshold, above which the power supply
V_UV_ACTUAL 92 Volts Typical DC start-up voltage based on standard value of
RUV_IDEAL 3.47 Mohms Calculated value for UV Lockout resistor

RUV_ACTUAL 3.60 Mohms Closest standard value of resistor to RUV_IDEAL

BIAS WINDING VARIABLES

VB 15.00 Volts Bias winding Voltage
NB 5 Number of Bias Winding Turns
PIVB 63 Volts Bias Rectifier Maximum Peak Inverse Voltage

INPUT INFO OUTPUT UNIT ACDC_PeakSwitch_031006_Rev1-1.xls; PeakSwitch

30.00

2.71 Amps Power Supply Output Current (corresponding to peak power)

27.00 27.00 Volts Minimum Output Voltage at Peak Power (Assuming output droop

Volts Nominal Output Voltage (at continuous power)

32.00 Watts Continuous Output Power

73.17 Watts Peak Output Power

PKS606Y

170 Volts Nominal Clamp Voltage

Continuous/Discontinuous Flyback Transformer Design
Spreadsheet

during peak load)

Enter 0.7 if no better data available

tighter tolerance)

(0.25 < KP < 6)

will start
RUV_ACTUAL

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES

Core Type EE25 EE25 User Selected Core Size(Verify

Core EE25
Bobbin EE25_BOBBIN P/N:

AE 0.404 cm^2 Core Effective Cross Sectional Area

P/N:

acceptable thermal rise under continuous
load conditions)
PC40EE25-Z
EE25_BOBBIN

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

TRANSFORMER SECONDARY DESIGN PARAMETERS

Lumped parameters

ISP 10.06 Amps Peak Secondary Current
ISRMS 5.44 Amps Secondary RMS Current
IRIPPLE 4.72 Amps Output Capacitor RMS Ripple Current
CMS 1089 Cmils Secondary Bare Conductor minimum

AWGS 19 AWG Secondary Wire Gauge (Rounded up to

VOLTAGE STRESS PARAMETERS

VDRAIN 624 Volts Maximum Drain Voltage Estimate

PIVS 127 Volts Output Rectifier Maximum Peak Inverse

circular mils
next larger standard AWG value)

(Assumes 20% zener clamp tolerance
and an additional 10% temperature
tolerance)

Voltage

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

9 Performance Data

All measurements performed at room temperature, 60 Hz input frequency.

9.1 Efficiency

84%
84%
83%
83%
82%
82%
81%

Efficiency (%)

81%
80%

100% Load 75% Load
50% Load 25% Load

80%
79%

80 100 120 140 160 180 200 220 240 260 280

AC Input Voltage

Figure 6 – Efficiency vs. Input Voltage, Room Temperature, 60 Hz.

9.1.1 Active Mode CEC Measurement Data
All single output adapters, including those provided with products for sale in California

after July 1st, 2006 must meet the California Energy Commission (CEC) requirement for
minimum active mode efficiency and no-load input power. Minimum active mode
efficiency is defined as the average efficiency of 25, 50, 75 and 100% of rated output
power, with the limit based on the nameplate output power:

Nameplate
Output (P

< 1 W
≥ 1 W to ≤ 49 W 0.09 × ln (PO) + 0.49 [ln = natural log]

> 49 W 0.84

)

O

Minimum Efficiency in Active Mode
of Operation

0.49 × P

O

For adapters that are single input voltage only, the measurement is made at the rated
single nominal input voltage (115 VAC or 230 VAC). For universal input adapters the
measurement is made at both nominal input voltages (115 VAC and 230 VAC).

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

To meet the standard, the measured average efficiency (or efficiencies for universal input
supplies) must be greater than or equal to the efficiency specified by the CEC/Energy
Star standard.

Percent of
Full Load

25 81.0% 80.5%
50 81.6% 81.5%
75 82.4% 82.8%

100 82.1% 83.4%

Average

CEC
specified
minimum
average
efficiency (%)

Efficiency (%)

115 VAC 230 VAC

81.8% 82%

80.2%

More states within the USA and other countries are adopting this standard. For the latest
up to date information please visit the PI Green Room:

http://www.powerint.com/greenroom/regulations.htm

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

9.2 No-load Input Power

0.22

0.20

0.18

0.16

0.14

0.12

0.10

0.08

Input Power (W)

0.06

0.04

0.02

0.00
80 100 120 140 160 180 200 220 240 260 280

AC Input Voltage

Figure 7 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.

9.3 Available Standby Output Power

The chart below shows the available output power vs. line voltage for input power levels
of 1 W and 3 W.

2.50

2.25

2.00

1.75

1.50

1.25

1.00

0.75

Available Output Power (W)

0.50

0.25

0.00
80 100 120 140 160 180 200 220 240 260 280

Figure 8 –- Available Output Power vs. Input Voltage for PIN of 1 W and 3 W.

Page 21 of 40

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

9.4 Regulation

9.4.1 Load Regulation

100.5%

100.0%

99.5%

99.0%

98.5%

98.0%

Regulation (%)

97.5%

97.0%

96.5%
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2

Figure 9 – Output Regulation vs. Load, Room Temperature.

9.4.2 Line Regulation

103%

Output Load (A)

115 VAC
230 VAC

102%

101%

100%

99%

98%

97%

Regulation (%)

96%

95%

94%

93%

80 100 120 140 160 180 200 220 240 260 280

AC Input Voltage

Figure 10 – Line Regulation, Room Temperature, Full Load. (32 W).

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

10 Thermal Performance

Temperature of key components, open frame room temperature and 85 VAC input.

Item

85 VAC

Ambient 25.2

D8 (Output Rectifier) 65.8

C12 (Output Capacitor) 47.0

U1 (PeakSwitch) 70.0

T1 (Transformer) 58.0

L1 (Common Mode

Choke)

C4 (Bulk Capacitor) 34.7

Temperature

(°C)

47.0

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

11 Waveforms

11.1 Drain Voltage and Current, Normal Operation

Figure 11 – 90 VAC, Full Load.

Upper: V
Lower: I

, 100 V / div.

DRAIN

, 0.5 A, 5 µs / div.

DRAIN

11.2 Output Voltage Start-up Profile

Figure 13 – Start-Up Profile, 90 VAC.

5 V, 5 ms / div.

Figure 12 – 265 VAC, Full Load.

Upper: V
Lower: I

, 200 V / div.

DRAIN

, 0.5 A, 5 µs / div.

DRAIN

Figure 14 – Start-Up Profile, 265 VAC.

5 V, 5 ms / div.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

11.3 Drain Voltage and Current Start-up Profile

Figure 15 – 90 VAC Input, 32 W Load.

Upper: V
Lower: I

, 100 V, 2 ms / div.

DRAIN

, 2 A / div.

DRAIN

Figure 16 – 265 VAC Input, 32 W Load.

Upper: V
Lower: I

11.4 Load Transient Response (1 A to 2 A Load Step)

Figure 17 – Transient Response, 90 VAC,

1 A to 2 A to 1 A Load Step.
Upper: Output Voltage, 1 V/div.
Lower: Load Current, 1 A, 50 ms/div.

Figure 18 – Transient Response, 265 VAC,

, 200 V, 2 ms / div.

DRAIN

, 2 A / div.

DRAIN

1 A to 2 A to 1 A Load Step.
Upper: Output Voltage, 1 V/div.
Lower: Load Current, 1 A, 50 ms/div.

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

11.5 Holdup Time

All measurements taken at 32 W output load.

Figure 19 – Holdup Time, 90 VAC.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 1 A/div.
Bottom Trace: AC Input Current, 5 A, 10 ms/div.

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11.6 AC Line Disturbance

All measurements taken at 32 W output load.

Figure 20 – Half-Cycle Dropout, 90 VAC, 60 Hz.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 2 A/div.
Bottom Trace: AC Input Voltage, 100 V, 20 ms/div.

Figure 22 – Half-Cycle Dropout, 216 VAC, 50 Hz.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 2 A/div.
Bottom Trace: AC Input Voltage, 200 V, 20 ms/div.

Figure 21 – Half-Cycle Dropout, 120 VAC, 60 Hz.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 2 A/div.
Bottom Trace: AC Input Voltage, 100 V, 20 ms/div.

Figure 23 – Half-Cycle Dropout, 240 VAC, 50 Hz.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 2 A/div.
Bottom Trace: AC Input Voltage, 200 V, 20 ms/div.

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

Figure 24 – Full Cycle Dropout, 120 VAC, 60Hz.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 2 A/div.
Bottom Trace: AC Input Voltage, 200 V, 20 ms/div.

Figure 26 – Line Sag from 120 VAC to 84 VAC
(50 cycles), 60 Hz.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 2 A/div.
Bottom Trace: AC Input Voltage, 100 V, 200 ms/div.

Figure 25 – Full Cycle Dropout, 240 VAC, 50 Hz.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 2 A/div.
Bottom Trace: AC Input Voltage, 200 V, 20 ms/div.

Figure 27 – Line Sag from 120 VAC to 48 VAC
(16 cycles), 60 Hz.
Top Trace: Output Voltage, 10 V/div.
Bottom Trace: AC Input Voltage, 100 V, 200 ms/div.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

Figure 28 – Line Swell from 240 VAC to 300 VAC
(500 msec), 50 Hz.
Top Trace: Output Voltage, 10 V/div.
Bottom Trace: AC Input Voltage, 500 V, 100 ms/div.

Figure 29 – Peak Drain Voltage During 300 VAC
Line Swell, 100 V, 2 µs/div.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

12.1.2 Measurement Results

Figure 32 – Output Ripple, 90 VAC, 60 Hz, Full

Load.
200 mV, 5 ms / div.

Figure 33 – Output Ripple, 265 VAC, 50 Hz, Full

Load.
200 mV, 2 ms / div.

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

13 Output Over-current Shutdown/Restart

Figure 34 – Supply Shutdown After Output Load

Step from 1.07 A to 2.8 A, 85 VAC.
Top Trace: Output Voltage, 10 V/div.
Bottom Trace: Output Current, 1 A, 20 ms/div.

Figure 36 – Output Recovery Following Over­Current Shutdown and AC Input Recycle, 115 VAC.
Top Trace: Output Voltage, 20 V/div.
Middle Trace: Output Current, 1 A/div.
Bottom Trace: AC Input Voltage, 100 V, 500 ms/div.

Figure 35 – Supply Shutdown After Output Load
Step from 1.07 A to 2.8 A, 265 VAC.
Top Trace: Output Voltage, 10 V/div.
Bottom Trace: Output Current, 1 A, 20 ms/div.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

14 Line Surge

Differential input line 1.2/50 µs surge testing was completed on a single test unit to
IEC61000-4-5, with 10 strikes per injection phase at 60 second intervals. Input voltage
was set at 230 VAC / 60 Hz. Output was loaded at 32 W and operation was verified
following each surge event.

Surge
Level (V)

+1kV 230 L to N 0 Pass

-1kV 230 L to N 0 Pass
+1kV 230 L to N 90 Pass

-1kV 230 L to N 90 Pass
+1kV 230 L to N 270 Pass

-1kV 230 L to N 270 Pass
+2kV 230 L, N to

+2kV 230 L, N to
+2kV 230 L, N to
+2kV 230 L, N to
+2kV 230 L, N to
+2kV 230 L, N to

Unit passes under all test conditions.

Input
Voltage
(VAC)

Injection
Location

GND
GND
GND
GND
GND
GND

Injection
Phase (°)

Test Result
(Pass/Fail)

0 Pass
0 Pass
90 Pass
90 Pass
270 Pass
270 Pass

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

15 Conducted EMI

For the measurements shown below, the power supply was resistively loaded to 32 W
and attached to the LISN via a 2-meter IEC line cord arranged in a serpentine pattern.
The power supply secondary return was hard-wired to the LISN ground using a 1-meter
cable.

Figure 37 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits.

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

Figure 38 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits.

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

16 Appendix

16.1 Heat Sink Drawing

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

17 Revision History

Date Author Revision Description & changes

17-Mar-06 PI SJ 1.0 First Release
24-Mar-06 PI SJ 1.1 Fix board picture and add

transformer suppliers
30-Mar-06 PI SJ 1.2 Format for printing
04-May-06 PI SJ 1.3 Updated PeakSwitch symbol

in Figure 2
22-Jun-06 PI SJ 1.4 Revised ground connection

on the circuit diagram in

Figure 2

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

Notes

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22-Jun-2006 EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply

Notes

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EP-93 – 30 V, 1.07 A, 2.7 A (peak), Universal Input Supply 22-Jun-2006

For the latest u pd ates, visit our website:

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. POWER INTEGRATIONS
MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT
LIMI TA TIO N, THE IM PL IE D WAR R AN TIES O F MER CH AN TA BIL I TY, F I TNE SS FOR A P AR TIC U LAR P UR POS E, AN D
NON-INFRINGEMENT OF THIRD PARTY RIGHTS.

www.powerint.com

PATENT INFORMAT I ON

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. P ower Int egra tion s gran ts its
customers a license under cer tain pate nt rights as set forth at http://www.pow erint.com/ip.htm.

Th e P I Lo g o,

Filterfuse, PI Ex p e r t

TOPSwitc h, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, Eco S m art, Clampless, E-Shield

and

PI FACTS

are trademarks of Power Inte g rations, Inc. Oth er trad emarks are property of th eir respective

companies. ©Copyright 2006 Power Integrations, Inc.

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