RDK-128 Power Integrations, RDK-128 Datasheet

KIT REF DESIGN 36-72W MOTOR DRVR

RDK-128

Manufacturer Part Number
RDK-128
Description
KIT REF DESIGN 36-72W MOTOR DRVR
Manufacturer
Power Integrations
Datasheets

Specifications of RDK-128

Main Purpose
Power Management, Motor Control
Embedded
No
Utilized Ic / Part
PKS606
Primary Attributes
Variable Speed 12V 36W DC Motor, 90 ~ 265 VAC
Secondary Attributes
External Potentiometer or Variable DC Voltage Speed Control
Lead Free Status / RoHS Status
Not applicable / Not applicable
Other names
596-1198
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.
Title
Specification
Application
Author
Document
Number
Date
Revision
Summary and Features
• Replaces a two-stage linear power supply and chopper circuit with a simple
• Eliminates the chopper circuits normally used to achieve variable-speed control
• Motor speed is controllable by a small potentiometer or a 3.6 V to 10 V variable
• Easily meets CISPR-22 / EN55022B limits with E-Shields and Frequency
single-stage design
of DC motors
DC voltage
jittering feature.
Reference Design Report for a 36 W
Continuous, 72 W Peak Power Supply
Using PKS606YN
90 – 265 VAC Input, 12 V, 36 W Continuous
(72 W Peak) Output
Variable Speed Motor Drive
Power Integrations Applications Department
RDR-128
August 16, 2007
1.0
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
Power Integrations
www.powerint.com

Related parts for RDK-128

RDK-128 Summary of contents

Page 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. ...

Page 2

... 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 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 16-Aug-07 Page ...

Page 3

... 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. Page RDR-128 Peak Variable Output Power Supply Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 4

... 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. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 16-Aug-07 ...

Page 5

... AMB Tel: +1 408 414 9200 Fax: +1 408 414 9201 Units Comment VAC 2 Wire – ± MHz bandwidth Measured OUT 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: kV Differential Mode: 2 Ω Common Mode: 12 Ω Free convection, sea level Power Integrations www.powerint.com ...

Page 6

... RDR-128 Peak Variable Output Power Supply 3 Schematic Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 2 – Schematic. 16-Aug-07 Page ...

Page 7

... 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. Page RDR-128 Peak Variable Output Power Supply Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 8

... LED of the optocoupler and thus reduces the supply’s output voltage applied at J3, the supply shuts down completely. Reducing the external control voltage after a shut down will start the power supply again. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ) of approximately 5 ...

Page 9

... PCB Layout Page RDR-128 Peak Variable Output Power Supply Figure 3 – Printed Circuit Layout. Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 10

... Wire Jumper, Non insulated, 22 AWG, 0 JP2 Wire Jumper, Non insulated, 22 AWG, 0 JP3 JP4 Wire Jumper, Non insulated, 22 AWG, 0.6 in Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 16-Aug-07 Mfg Mfg Part Number Panasonic ECK- ANA101MB Carli PX684K3ID6 ...

Page 11

... Tel: +1 408 414 9200 Fax: +1 408 414 9201 ELF15N010A 2N3904RLRAG CFR-25JB-1M3 CFR-50JB-62R CFR-12JB-2R2 CFR-25JB-2M2 CFR-25JB-2M4 CFR-25JB-4K7 CFR-12JB-20R CFR-50JB-68R MFR-25FBF- 1K21 CFR-25JB-2K0 296UD502B1N CFR-25JB-30R MFR-25FBF- 1K00 CL-120 PMSSS 440 0031 PH YW-360-02B SNX R1365 PKS606YN PC817XJ0000F LMV431ACZ P6KE200ARLG 1N5241B-T FWSS 004 3049 Power Integrations www.powerint.com ...

Page 12

... Magnet Wire: #31 AWG [4] Magnet Wire: #29 AWG [5] Triple Insulated Wire: #23 AWG [6] Tape, 3M 1298 Polyester Film, 2.0 mil thick, 10.7 mm wide [7] Varnish Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 4 – Transformer Electrical Diagram. 1 second, 60 Hz, from Pins 1-5 to Pins 7 and 10 Pins 1-2, all other windings open, measured at 100 kHz, 0 ...

Page 13

... RDR-128 Peak Variable Output Power Supply Lp = 148 uH Figure 5 – Transformer Build Diagram. Tel: +1 408 414 9200 Fax: +1 408 414 9201 19T #31AWG 1/2 Primary: (filled #29AWG Shield: (filled #23AWG_TIW Secondary: (in 1.5 layers) Bias #29AWG (scatterd) (Spread) 1/2 Primary: 19T #31AWG (filled) Power Integrations www.powerint.com ...

Page 14

... Apply 3 layers of item [6], 3M 1298 Polyester Film tape, for insulation Core Assembly Assemble and secure core halves. Varnish Dip varnish assembled transformer with item [7], varnish. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 16-Aug-07 Winding direction is Page ...

Page 15

... Bias winding Voltage 5 Number of Bias Winding Turns 65 Volts Bias rectifier Maximum Peak Inverse Voltage EE25 User Selected Core Size(Verify acceptable thermal rise under continuous load conditions) EE25 P/N: PC40EE25-Z EE25_BOBBIN P/N: EE25_BOBBIN Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 16

... TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP ISRMS IRIPPLE CMS AWGS VOLTAGE STRESS PARAMETERS VDRAIN PIVS Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 0.404 cm^2 Core Effective Cross Sectional Area 7.34 cm Core Effective Path Length 1420 ...

Page 17

... Full Load 115 230 VAC VAC 25 80.2 80.2 50 81.2 79.8 75 81.3 80.7 100 78.2 80.7 Table 1 – Efficiency Data. Efficiency 1.000 1.500 2.000 2.500 Load (A) Tel: +1 408 414 9200 Fax: +1 408 414 9201 115 VAC 230 VAC 3.000 Power Integrations www.powerint.com ...

Page 18

... RDR-128 Peak Variable Output Power Supply 84.0% 82.0% 80.0% 78.0% 76.0% 74.0% 72.0% 70.0% 5 Figure 7 – Efficiency vs. Output Voltage with Full Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Efficiency vs. Output Voltage Output Voltage (V) 16-Aug-07 115 VAC ...

Page 19

... RDR-128 Peak Variable Output Power Supply No-load Input Power 125 145 165 185 205 Line Voltage (VAC) Load Regulation 0.500 1.000 1.500 2.000 Load (A) Tel: +1 408 414 9200 Fax: +1 408 414 9201 225 245 265 285 115 VAC 230 VAC 2.500 3.000 Power Integrations www.powerint.com ...

Page 20

... Figure 10 – Line Regulation, Room Temperature, Full Load. 9.4 Adjustable Output Voltage Characteristics 9.4.1 Resistor Control Figure 11 – Output Voltage vs. Potentiometer Resistance. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Line Regulation 135 185 Line Voltage (VAC) Resistor Control Characteristic Potentiometer, R Resistance (kΩ ...

Page 21

... Control Voltage (V) Temperature (°C) Item 90 VAC 230 VAC Ambient 40 PeakSwitch, (U1) 106 Output Diode, (D9) 91 Transformer (T1) 93 Clamp (VR1) 115 86 Tel: +1 408 414 9200 Fax: +1 408 414 9201 6.00 6.50 7.00 7.50 40 100 100 94 113 81 Power Integrations www.powerint.com ...

Page 22

... RDR-128 Peak Variable Output Power Supply 90 VAC load, 21ºC Ambient Figure 13 – Infrared Thermograph of Open Frame Operation at Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 16-Aug-07 Page ...

Page 23

... RDR-128 Peak Variable Output Power Supply – Figure 15 90 VAC Upper: V Lower: I Figure 17 – 230 VAC Upper: V Lower: I Tel: +1 408 414 9200 Fax: +1 408 414 9201 = 2 out o , 100 V DRAIN , 1 div, 5 µs / div. DRAIN = 2 out o , 100 V DRAIN , 1 div, 5 µs / div. DRAIN Power Integrations www.powerint.com ...

Page 24

... Middle div. DRAIN Lower 100 div) DRAIN Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 19 – Start-up Profile, 230 VAC Upper Trace: Output Voltage div. Middle Trace: Output Current 1 A /div. Lower Trace: DC Bus Voltage 100 V /div. ...

Page 25

... Figure 25 – 230 VAC Input, V Upper Trace: DC Bus Voltage 100 V / div. Middle Trace: V Lower Trace div. Tel: +1 408 414 9200 Fax: +1 408 414 9201 , 500 mV / div. (AC coupled) out , div. DRAIN =11 V out Ripple div. out =12 A out Power Integrations www.powerint.com ...

Page 26

... The waveform shown below illustrates the power supply’s latching shutdown feature. This feature is invaluable in a motor application due to the short circuit condition that can occur if the motor were to become jammed. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 26 – ...

Page 27

... Figure 28 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter. (Modified with wires for ripple measurement and two parallel decoupling capacitors added) Page RDR-128 Peak Variable Output Power Supply Tel: +1 408 414 9200 Fax: +1 408 414 9201 Probe Ground Probe Tip Power Integrations www.powerint.com ...

Page 28

... Figure 31 – 230 VAC Input, V out Upper Trace: V Ripple, 500 mV / div. out Lower Trace 100 V /div. Drain (5 µs / div) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 30 – 90 VAC Input Figure 32 – 230 VAC Input 16-Aug-07 =2 ...

Page 29

... Figure 33 – Conducted EMI, Maximum Steady State Load, 90 VAC, 60 Hz, and EN55022 B Limits. Figure 34 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits. Page RDR-128 Peak Variable Output Power Supply Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 30

... RDR-128 Peak Variable Output Power Supply 12 Revision History Date Author 16-Aug-07 SK Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Revision Description & changes 1.0 Initial Publication 16-Aug-07 Reviewed Page ...

Page 31

... Page RDR-128 Peak Variable Output Power Supply Notes Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 32

... RDR-128 Peak Variable Output Power Supply For the latest updates, visit our website: www.powerint.com 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 ...

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