RDK-641 Power Integrations

Reference Design Report for a 40 W Power TM Supply Using InnoSwitch 3-Pro Title INN3377CH301 and Microchips PIC16F18325 Microcontroller 85 VAC to 265 VAC Input Specification 3 V to 8 V, 5 A 8 V to 20 V Constant Power Application Programmable Industrial Power Supply Author Applications Engineering Department Document RDR-641 Number Date August 1, 2018 Revision 1.2 Summary and Features InnoSwitch3-Pro is industrys first AC/DC IC with isolated, safety rated integrated feedback 2 and I C interface Completely programmable and configurable Controllable output voltage and output current Telemetry (read-back) feature with fully configurable protection features All the benefits of secondary-side control with the simplicity of primary-side regulation Insensitive to transformer variation Built in synchronous rectification driver for high efficiency Easily meets DOE6 and CoC V5 2016 efficiency standards <30 mW no-load input power Integrated thermal protection Primary sensed line overvoltage protection rd 3 Party Microcontroller Microchip PIC16F18325 PATENT INFORMATION 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. Power Integrations grants its customers a license under certain patent rights as set forth at RDR-641 40 W InnoSwitch3-Pro Power Supply 01-Aug-18 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 InnoSwitch3-Pro IC Primary ........................................................................... 8 4.3 InnoSwitch3-Pro IC Secondary ....................................................................... 8 4.4 Digitally Controlled Feature .......................................................................... 10 4.5 Debounce Switches ...................................................................................... 10 4.6 Headers and Jumpers Settings ..................................................................... 10 5 PCB Layout ........................................................................................................ 11 6 Bill of Materials .................................................................................................. 12 7 Transformer (T2) Specification ............................................................................ 14 7.1 Electrical Diagram ........................................................................................ 14 7.2 Electrical Specifications ................................................................................ 14 7.3 Material List ................................................................................................ 14 7.4 Transformer Build Diagram .......................................................................... 15 7.5 Transformer Construction ............................................................................. 15 7.6 Winding Illustrations .................................................................................... 16 8 Common Mode Choke Specifications .................................................................... 22 8.1 108 H Common Mode Choke (L2) ............................................................... 22 8.1.1 Electrical Diagram ................................................................................. 22 8.1.2 Electrical Specifications.......................................................................... 22 8.1.3 Material List .......................................................................................... 22 8.1.4 Illustrations .......................................................................................... 22 8.2 16 mH Common Mode Choke (L1) ................................................................ 23 8.2.1 Electrical Diagram ................................................................................. 23 8.2.2 Electrical Specifications.......................................................................... 23 8.2.3 Materials List ........................................................................................ 23 8.2.4 Winding Instructions ............................................................................. 23 9 Transformer Design Spreadsheet ........................................................................ 24 10 Performance Data ........................................................................................... 28 10.1 Efficiency vs. Load ....................................................................................... 28 10.1.1 Output: 3 V / 5 A .................................................................................. 28 10.1.2 Output: 5 V / 5 A .................................................................................. 29 10.1.3 Output: 8 V / 5 A .................................................................................. 30 10.1.4 Output: 15 V / 2.666 A .......................................................................... 31 10.1.5 Output: 20 V / 2 A ................................................................................ 32 10.2 Efficiency vs. Line ........................................................................................ 33 10.3 Line Regulation............................................................................................ 34 10.3.1 Output: 3 V / 5 A .................................................................................. 34 10.3.2 Output: 5 V / 5 A .................................................................................. 35 Power Integrations, Inc. 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