Power Integrations RDR-128 User Manual
Reference Design Report for a 36 W
Title
Continuous, 72 W Peak Power Supply
Using PKS606YN
90 – 265 VAC Input, 12 V, 36 W Continuous
Specification
(72 W Peak) Output
Application
Variable Speed Motor Drive
Author Power Integrations Applications Department
Document
RDR-128
Number
Date August 16, 2007
Revision 1.0
Summary and Features
• Replaces a two-stage linear power supply and chopper circuit with a simple
single-stage design
• Eliminates the chopper circuits normally used to achieve variable-speed control
of DC motors
• Motor speed is controllable by a small potentiometer or a 3.6 V to 10 V variable
DC voltage
• Easily meets CISPR-22 / EN55022B limits with E-Shields and Frequency
jittering feature.
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
.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07
Table of Contents
1 Introduction.................................................................................................................4
2 Power Supply Specification........................................................................................5
3 Schematic ...................................................................................................................6
4 Circuit Description ......................................................................................................7
4.1 Input EMI Filtering...............................................................................................7
4.2 PeakSwitch Primary............................................................................................7
4.3 Under-voltage Protection and Fast AC Reset circuit...........................................7
4.4 Output Rectification and Filtering ........................................................................8
4.5 Output Feedback.................................................................................................8
5 PCB Layout ................................................................................................................9
6 Bill of Materials.........................................................................................................10
7 Transformer Specification.........................................................................................12
7.1 Electrical Diagram.............................................................................................12
7.2 Electrical Specifications.....................................................................................12
7.3 Materials............................................................................................................12
7.4 Transformer Build Diagram ...............................................................................13
7.5 Transformer Construction..................................................................................14
8 Transformer Spreadsheet.........................................................................................15
9 Performance Data ....................................................................................................17
9.1 Efficiency...........................................................................................................17
9.2 No-load Input Power..........................................................................................19
9.3 Regulation.........................................................................................................19
9.3.1 Load...........................................................................................................19
9.3.2 Line ............................................................................................................20
9.4 Adjustable Output Voltage Characteristics........................................................20
9.4.1 Resistor Control .........................................................................................20
9.4.2 External Voltage Control ............................................................................21
9.5 Thermal Performance........................................................................................21
10 Waveforms............................................................................................................23
10.1 Drain Voltage and Current, Normal Operation...................................................23
10.2 Output Voltage and Current Start-up Profile......................................................24
10.3 Drain Voltage and Current Start-up Profile........................................................24
10.4 Transient Response ..........................................................................................25
10.5 Output Voltage and DC Bus Voltage Ripple......................................................25
10.6 Latching Shutdown Operation ...........................................................................26
10.7 Output Ripple Measurements............................................................................27
10.7.1 Ripple Measurement Technique ................................................................27
10.7.2 Measurement Results ................................................................................28
11 Conducted EMI.....................................................................................................29
12 Revision History....................................................................................................30
Page 2 of 32
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16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply
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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RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07
1 Introduction
This document is an engineering report describing a motor drive power supply capable of
delivering up to 36 W of continuous power and up to 72 W of peak power, utilizing a
PKS606YN device. This power supply is intended as a demonstration platform for the
PeakSwitch family of devices and their application in motor drives. The PeakSwitch
family of devices is ideally suited to this role due to their ability to provide very high peak
power for short periods of time, as is often encountered in motor drive applications.
This document contains the power supply specification, schematic, bill of materials,
transformer documentation, printed circuit board layout and performance data.
Figure 1 – Populated Circuit Board Photograph.
Page 4 of 32
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16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply
2 Power Supply Specification
Description Symbol Min Typ Max Units Comment
Input
Voltage
Frequency
No-load Input Power (230 VAC) 0.3 W
Output
Output Voltage 1
Output Ripple Voltage 1
Continuous Output Current 1
Peak Output Current 1
Total Output Power
Continuous Output Power
Peak Output Power
Efficiency
Full Load
Environmental
Conducted EMI
Safety
Surge 2 kV
Ambient Temperature
V
f
LINE
IN
90 265 VAC
47 50/60 64 Hz
2 Wire – no P.E.
11.5 12 12.5 V
V
OUT1
V
RIPPLE1
I
OUT1
I
OUTPK
P
OUT
P
OUT_PEAK
800 mV
3 A
6.0 A
36 W
72 W
20 MHz bandwidth
η
80 %
Measured at P
Meets CISPR22B / EN55022B
T
AMB
Designed to meet IEC950, UL1950
0 40
Class II
1.2/50 µs surge, IEC 1000-4-5,
Series Impedance:
Differential Mode: 2 Ω
o
C
Common Mode: 12 Ω
Free convection, sea level
± 5%
OUT
25
o
C
Page 5 of 32
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RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07
3 Schematic
Figure 2 – Schematic.
Page 6 of 32
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16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply
4 Circuit Description
The motor drive power supply shown in Figure 1 is a switch mode power supply design
utilizing the flyback topology.
4.1 Input EMI Filtering
Differential mode EMI filtering is provided by X-capacitor C3. Y-capacitors C1, C2, C10
and C12, together with the common-mode choke L1, provide common-mode EMI
filtering. Additionally the transformer E-Shields™, together with the frequency jittering
features, provide adequate EMI margins.
4.2 PeakSwitch Primary
Fuse F1 protects the power supply from a catastrophic failure due to a short circuit fault.
A high voltage DC bus is created from the AC line voltage by the full-wave rectifier
formed by diodes D1-D4. Capacitor C4 smoothes and filters the rectified AC voltage.
The PKS606YN (U1) integrates a high voltage MOSFET, along with startup and all
necessary control circuitry.
During the MOSFET’s on-time, current flows through the primary of transformer T1,
storing energy in the transformer core.
During the turn off event, the voltage across the primary winding reverses. A voltage
equal to the sum of DC bus voltage and the reflected output voltage (VOR) appears
across the DRAIN and SOURCE of the PeakSwitch, with an additional spike generated
by the leakage inductance. A primary clamp circuit formed by D6, VR1, R3 and C5 limits
this voltage and resets the leakage energy prior to the next switching cycle.
Diode D7 rectifies the supply’s bias winding while capacitor C9 provides DC filtering.
This bias supply is connected to the PeakSwitch’s BP pin via R7, which powers the
device during normal operation.
4.3 Under-voltage Protection and Fast AC Reset circuit
Under-voltage shutdown is implemented by a separate line rectifying diode, D5, which
charges capacitor C7. Resistors R5 and R6 program the UV start-up voltage to
approximately 104 VDC, which is the DC voltage across C7, at which a current equal to
25 µA flows into the EN/UV pin.
This separate AC line sense network (formed by D5, C7) allows the PeakSwitch to
identify the cause of a fault condition. If the input voltage is above the under-voltage
threshold and the EN/UV pin has not been pulled low for 30 ms, a fault condition is
assumed, and the PeakSwitch latches off. Once the supply is latched off, the AC line
voltage must be removed to allow capacitor C7 to discharge and allow the current into
the EN/UV pin to fall below 25 µA.
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RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07
If the EN/UV pin has not been pulled low for 30 ms and the input voltage is below the
under-voltage threshold, then the loss of regulation is assumed to be due to a low line
condition, and the PeakSwitch will stop switching until the under-voltage threshold is
exceeded again.
4.4 Output Rectification and Filtering
Diode D9 rectifies the output voltage while capacitors C13 and C14 provide output
filtering. The output capacitor current ripple rating is chosen t6 79S327.74 Bicsin
in52.(mume radedm)]TJ/T64 1 Tf7183 0 TD0.0001 Tc0 Tw(coatiuous/avertag )Tj/TT2 1 Tf58.32 0 TD-0.0005 Tc000077 Tw[a ladg. Resi str R93 andct
Page 8 of 32
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16-Aug-07 RDR-128 36 W, 72 W Peak Variable Output Power Supply
5 PCB Layout
Figure 3 – Printed Circuit Layout.
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RDR-128 36 W, 72 W Peak Variable Output Power Supply 16-Aug-07
6 Bill of Materials
Item Qty Ref Description Mfg Mfg Part
Number
1 2 C1 C2 100 pF, Ceramic, Y1 Panasonic ECK-
ANA101MB
2 1 C3 680 nF, 275 VAC, Film,MPX
Series, X2
3 1 C4 180 uF, 400 V, Electrolytic, Low
ESR, (18 x 40)
4 1 C5 2.2 nF, 1 kV, Disc Ceramic NIC Components
Carli PX684K3ID6
Nippon Chemi-Con EPAG401ELL18
1MM40S
NCD222K1KVY
Corp
5FF
5 1 C6 4700pF, 1 kV, Thru Hole, Disc
Ceramic
6 1 C7 100 nF, 400 V, Film Panasonic ECQ-E4104KF
7 1 C8 220 nF, 50 V, Ceramic, Z5U, 0.2"
L.S.
8 1 C9 47 uF, 35 V, Electrolytic, Gen.
Purpose, (5 x 11)
9 2 C10 C12 1 nF, Ceramic, Y1 Panasonic ECK-
10 1 C11 330 pF, 1 kV, Disc Ceramic Vishay 562R5GAT33
11 2 C13 C14 680 uF, 25 V, Electrolytic, Very
Low ESR, 23 mOhm, (10 x 20)
12 1 C15 1.0 uF, 50 V, Ceramic, X7R Epcos B37984M5105K
13 5 D1 D2 D3
D4 D5
14 1 D6 800 V, 1 A, Fast Recovery Diode,
15 3 D7 D8 D10 75 V, 300 mA, Fast Switching,
16 1 D9 60 V, 10 A, Schottky, TO-220AC Vishay MBR1060
17 1 F1 3.15 A, 250V, Slow, TR5 Wickman 3721315041
18 1 HS PAD1 HEATSINK PAD, TO-220, Sil-Pad
19 1 HS1 HEATSINK/Alum, TO220 1 hole,
20 1 HS2 HEATSINK/Alum, TO220 1 hole,
21 1 J1 3 Position (1 x 3) header, 0.156
22 2 J2 J3 2 Position (1 x 2) header, 0.156
23 2 JP1 JP5 Wire Jumper, Non insulated, 22
24 1 JP2 Wire Jumper, Non insulated, 22
25 2 JP3 JP4 Wire Jumper, Non insulated, 22
1000 V, 1 A, Rectifier, DO-41 Vishay 1N4007
500 ns, DO-41
DO-35
1000
2 mtg pins
2 mtg pins
pitch, Vertical
pitch, Vertical
AWG, 0.4 in
AWG, 0.3 in
AWG, 0.6 in
Vishay/Sprague 562R5GAD47
Kemet C322C224M5U5
CA
Panasonic ECA-1VHG470
ANA102MB
Nippon Chemi-Con EKZE250ELL68
1MJ20S
000
Diodes Inc. FR106
Vishay 1N4148
Bergpuist 1009-58
Clark Precision
Sheetmetal
Clark Precision
Sheetmetal
Molex 26-48-1031
Molex 26-48-1021
Alpha 298
Alpha 298
Alpha 298
60-00012-00
60-00020-00
Page 10 of 32
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