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| Design Idea DI-134 PeakSwitch Application Audio Device (R) Audio Amplifier Power Supply Power Output 20 W, 43 W peak Input Voltage 90-265 VAC Output Voltage 12 V Topology Flyback PKS606P Design Highlights * Delivers>2Xpeakpowerwithoutoutputdistortion * Universalinputvoltagerangeoperationallowsasingle designtobesoldworldwide * Highefficiency(>79%)acrossentireinputrange * MeetsEN55022BconductedEMIlimits * Auto-restartfeatureallowsindefinitelyshortedoutput * Thermalshutdownprotectssupplyandamplifier Operation TheisolatedflybackconvertershowninFigure1wasdesigned aroundamemberofthePeakSwitchICfamily,thePKS606P (U1).AdeviceinthePpackage(8-pinDIP)wasselectedto minimizethecostandsizeoftheheatsinkrequiredforpeak powerdelivery. The input circuitry consists of a fuse (F1) and EMI filter components(R6,C9,L8,L4,C12,R9,R8andC13).TheAC inputisrectified(D1-D4)andfiltered(C2)andconnected acrosstheprimarysidepowercomponents(T1andU1). Duringtheflybackportionofeachswitchingcycle,anRCDZenerclampcircuit(L2,D5,R7,C11andVR1)protectsthe MOSFET integrated within U1. Ferrite bead L2, and RC C11 470 pF 1 kV D1-D4 1N4005 C2 150 F 400 V R1 3.9 M 1/8 W 2 EE25 T1 9,10 snubberR7andC11reduceEMIbydampinghigh-frequency ringing.CapacitorC4decouplestheBYPASS(BP)pinof U1, which is the IC's internally regulated supply node. Anintegrated,high-voltagecurrentsourceprovidesinitial operatingpowertoU1.AbiaswindingonT1(pins4and 5), D6, C5 and R3 provide operating current to U1, after initial startup. Output voltage feedback is coupled across thesafetyisolationbarrierbyU2.TransistorQ1,C19,R14 and D9 prevent the high-frequency gain loss that the U2 phototransistornormallyexperiences,whichpreventsgroups ofenabledanddisabledswitchingcycles(pulsebunching). Using the signal on the EN/UV pin, the controller within U1regulatestheoutputvoltagebyenablinganddisabling MOSFETswitchingcycles. Onthesecondarysideoftheisolationbarrier,D7rectifiesthe outputofT1andchargesC7andC16.Thesnubbercircuit (R5andC10)acrossD7attenuatesthehighfrequencyring thatoccurswhenD7turnsoff. Outputvoltagefeedbackisderivedfromtwoseparatecircuits. ThecircuitformedbyVR2,theLEDinU2,C19andR16 providesthehighfrequency(HF)portionofthefeedback R5 10 1/2 W C10 1.2 nF 100 V VR2 1N5238B 8.7 V VR3 1N53538 16 V 12 V, 1.7 A 3.6 A PK C12 2.2 nF 1 kV R9 3.3 1/8 W VR1 P6KE200A 200 V D5 1N4937 L2 3.3 H 3A FB R8 22 1/2 W R7 300 1/8 W 3 6,7,8 4 D7 SB580 R10 2 k 5 R4 1 k R11 1 k R12 8.45 k 1% L4 5 mH D PeakSwitch U1 PKS606P EN/UV BP U2A PC817D D6 1N4148 C6 2.2 nF 250 VAC C17 150 nF 50 V L8 1.8 H C9 220 nF 275 VAC R6 2.2 M 1/8 W C13 39 pF 1 kV R3 4.7 k U2B PC817D Q1 2N3904 C7 220 F 25 V C16 220 F 25 V S C4 330 nF 50 V C5 47 F 35 V R14 51 k F1 2A R15 20 1/8 W D9 1N4148 C19 470 nF 50 V R16 1 k U3 TLV431 C18 6.8 nF 50 V R13 1 k 1% RTN PI-4580-022307 L N Figure 1. 20 W Continuous, 43 W Peak Audio Amplifier Power Supply, Designed Around a PKS606P Device. February 2007 DI-134 DI-89 DI-134 signal. The circuit formed by R10, U3 and its associated components provides the low frequency (LF) portion of the feedbacksignalanddeterminestheDCregulationsetpoint. The HF circuit gives the supply good transient load responsiveness.TheLFcircuitgivesthesupplygoodoutput voltageaccuracy.Bothcircuitsworkbyforwardbiasingthe LEDinU2whenevertheoutputvoltageexceedsthesetpoint value.TheseriesvoltagedropsacrossVR2,theU2LEDand R16 determine the set point for the HF circuit.The voltage divider(R12andR13)andU3determinethesetpointforthe LF circuit. Capacitor C17 is physically located near the HF circuit, and attenuates noise that could falsely trigger its set pointthreshold.ZenerdiodeVR3clampstheoutputvoltage at 16V, if the feedbackloop becomes an open circuit, until auto-restartactivates(occursafternocycleshavebeenskipped for30ms). * Thecoresizeandthewindingwirediametersizes werechosenbasedontheaverageofthepeakandthe continuousoutputpower. * Thenumberofturnsintheprimaryandsecondary windingsandtheprimaryinductancevalueswere chosenbasedonthepeakoutputpower. * DiodeD5mustbeanultrafastdiodewithareverse recoverytimeof<75ns. PI-4587-022207 82.5 82 Efficiency (%) 81.5 81 80.5 80 79.5 79 Efficiency @ VAC = 230 V Efficiency @ VAC = 115 V Key Design Points * ThevaluesforR11andR16werechosensothatthevoltage onthecathodeoftheLEDinU2isabout2.2V. TRANSFORMER PARAMETERS EE25 Core NC-2H or Equivalent, gapped for ALG of Material 105 nH/t2 Bobbin Winding Details EE25, 10 pin 1/2 Primary: 26T, 27 AWG, 1 layer, tape Bias: 8T X2, 29 AWG, tape Secondary: 6T, X4, 23 AWG TIW, 2 layers Shield: 7T X4, 29 AWG, tape 1/2 Primary: 26T, 27 AWG, 1 layer 0 0.5 1 1.5 2 Output Current (A) Figure 2. Efficiency vs. Load, at Standard Line Voltages. PI-4588-022207 80 70 60 50 40 QP AV QP dBV 30 20 10 0 -10 -20 0.15 1.0 10.0 70.0 AV Primary 370 mH 12% Inductance Primary Resonant 180 kHz (minimum) Frequency Leakage 8 mH (maximum) Inductance Table 2. Transformer Parameters. For the latest updates, visit www.powerint.com MHz Figure 3. Worst Case Conducted EMI (230 VAC). 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 LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. The products and applications illustrated herein (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 ExpertandPI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)2007, Power Integrations, Inc. Rev. A 02/07 Power Integrations 5245 Hellyer Avenue San Jose, CA 95138 Phone: 1-408-414-9200 Apps: 1-408-414-9660 Apps Fax: 1-408-414-9760 For a complete listing of worldwide sales offices, please visit www.powerint.com |
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