Title
Reference Design Report for a 40 W Power
Supply Using InnoSwitch
TM
3-Pro
INN3377C–H301 and Microchip’s
PIC16F18325 Microcontroller
85 VAC to 265 VAC Input;
3 V to 8 V, 5 A; 8 V to 20 V Constant Power
Programmable Industrial Power Supply
Applications Engineering Department
RDR-641
August 1, 2018
1.2
Specification
Application
Author
Document
Number
Date
Revision
Summary and Features
InnoSwitch3-Pro is industry’s first AC/DC IC with isolated, safety rated integrated feedback
and I
2
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
3
rd
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
https://www.power.com/company/intellectual-
property-licensing/.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
RDR-641 40 W InnoSwitch3-Pro Power Supply
01-Aug-18
Table of Contents
1
2
3
4
Introduction .........................................................................................................5
Power Supply Specification ...................................................................................6
Schematic ............................................................................................................7
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.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
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01-Aug-18
RDR-641 40 W InnoSwitch3-Pro Power Supply
10.3.3 Output: 8 V / 5 A .................................................................................. 36
10.3.4 Output: 15 V / 2.666 A .......................................................................... 37
10.3.5 Output: 20 V / 2 A ................................................................................ 38
10.4 Load Regulation .......................................................................................... 39
10.4.1 Output: 3 V .......................................................................................... 39
10.4.2 Output: 5 V .......................................................................................... 40
10.4.3 Output: 8 V .......................................................................................... 41
10.4.4 Output: 15 V ........................................................................................ 42
10.4.5 Output: 20 V ........................................................................................ 43
10.5 No-Load Input Power at 5 VOUT................................................................... 44
10.6 Average Efficiency ....................................................................................... 45
10.6.1
Average Efficiency Requirements ........................................................... 45
10.7 Average and 10% Efficiency (On the Board) at 115 VAC Input ....................... 45
10.7.1 Output: 3 V .......................................................................................... 45
10.7.2 Output: 5 V .......................................................................................... 45
10.7.3 Output: 8 V .......................................................................................... 45
10.7.4 Output: 15 V ........................................................................................ 46
10.7.5 Output: 20 V ........................................................................................ 46
10.8 Average and 10% Efficiency (On the Board) at 230 VAC Input ....................... 46
10.8.1 Output: 3 V .......................................................................................... 46
10.8.2 Output: 5 V .......................................................................................... 46
10.8.3 Output: 8 V .......................................................................................... 46
10.8.4 Output: 15 V ........................................................................................ 47
10.8.5 Output: 20 V ........................................................................................ 47
10.9 CV/CC ......................................................................................................... 48
10.9.1 Output: 3 V (CC Programmed to 5.1 A, V
KP
Programmed to 7 V) .............. 48
10.9.2 Output: 5 V (CC Programmed to 5.1 A, V
KP
Programmed to 7 V) .............. 49
10.9.3 Output: 8 V (CC Programmed to 5.1 A, V
KP
Programmed to 7 V) .............. 50
10.9.4 Output: 15 V (CC Programmed to 5.1 A, V
KP
Programmed to 7 V) ............ 51
10.9.5 Output: 20 V (CC Programmed to 5.1 A, V
KP
Programmed to 7 V) ............ 52
11
Thermal Performance in Open Case ................................................................. 53
11.1 85 VAC Input 3 V / 5 A ................................................................................ 53
11.2 265 VAC Input 3 V / 5 A ............................................................................... 53
11.3 85 VAC Input 5 V / 5 A ................................................................................ 54
11.4
265 VAC Input 5 V / 5 A ............................................................................... 54
11.5 85 VAC Input 8 V / 5 A ................................................................................ 55
11.6 265 VAC Input 8 V / 5 A ............................................................................... 55
11.7 85 VAC Input 15 V / 2.666 A ........................................................................ 56
11.8 265 VAC Input 15 V / 2.666 A ...................................................................... 56
11.9 85 VAC Input 20 V / 2 A ............................................................................... 57
11.10
265 VAC Input 20 V / 2 A ......................................................................... 57
12
Waveforms ..................................................................................................... 58
12.1 Load Transient Response (PCB End) ............................................................. 58
Power Integrations
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www.power.com
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RDR-641 40 W InnoSwitch3-Pro Power Supply
01-Aug-18
12.2 Switching Waveforms................................................................................... 61
12.2.1 Drain Voltage and Current ..................................................................... 61
12.2.2 Drain Voltage and Current Start-up ........................................................ 63
12.2.3 SR FET Voltage ..................................................................................... 64
12.2.4 Output Voltage and Current Start-up (On the Board) ............................... 67
12.3 Output Ripple Measurements........................................................................ 68
12.3.1 Ripple Measurement Technique ............................................................. 68
12.3.2 Ripple Amplitude vs. Line ...................................................................... 69
13
Conducted EMI ............................................................................................... 72
13.1 Floating Output ........................................................................................... 72
13.1.1 Output: 8 V / 5 A .................................................................................. 72
13.1.2
Output: 20 V / 2 A ................................................................................ 74
13.2 Artificial Hand .............................................................................................. 76
13.2.1 Output: 8 V / 5 A .................................................................................. 76
13.2.2 Output: 20 V / 2 A ................................................................................ 78
13.3 Earth Ground............................................................................................... 80
13.3.1 Output: 8 V / 5 A .................................................................................. 80
13.3.2 Output: 20 V / 2 A ................................................................................ 82
14
Line Surge ...................................................................................................... 84
14.1 Differential Surge......................................................................................... 84
14.2 Common Mode Surge................................................................................... 84
15
Revision History .............................................................................................. 85
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.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page
4 of 86
01-Aug-18
RDR-641 40 W InnoSwitch3-Pro Power Supply
1
Introduction
This document is an engineering report describing a 5 A CV/CC charger (3 V to 8 V
range), which switches to constant power in the 8 V to 20 V range
using the InnoSwitch3-
Pro and Microchip’s PIC16F18325 microcontroller. PIC16F18325 controls the
InnoSwitch3-Pro via an I
2
C interface, programming its COMMAND and telemetry
registers. This design shows the high power density and efficiency that is possible from
the high level of integration in the InnoSwitch3-Pro controller. The report contains the
power supply specification, schematic, bill of materials, transformer documentation,
printed circuit layout, and performance data.
Figure 1 –
Populated Circuit Board Photograph, Top.
(DER-641 is equivalent to RD-641.)
Figure 2 –
Populated Circuit Board Photograph, Bottom.
Page
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