DAK-68A Power Integrations, DAK-68A Datasheet

KIT DESIGN ACCELERATOR POE CONV

DAK-68A

Manufacturer Part Number
DAK-68A
Description
KIT DESIGN ACCELERATOR POE CONV
Manufacturer
Power Integrations
Series
DPA-Switch®r
Datasheets

Specifications of DAK-68A

Main Purpose
Special Purpose DC/DC, Power Over Ethernet
Outputs And Type
1, Non-Isolated
Power - Output
6.6W
Voltage - Output
3.3V
Current - Output
2A
Voltage - Input
36 ~ 57V
Regulator Topology
Flyback
Frequency - Switching
400kHz
Board Type
Bare (Unpopulated) and Fully Populated
Utilized Ic / Part
DPA423, DPA424, DPA425
Lead Free Status / RoHS Status
Not applicable / Not applicable
Other names
596-1007
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.
Summary and Features
Title
Specification Input: 36-57 VDC, Output: 3.3 V / 2 A
Application
Author
Document
Number
Date
Revision
• High efficiency, low parts count and low cost power supply
• Ideally suited for PoE, VoIP, standby and other distributed 48 V DC-DC
• DPA-Switch Integrates
• Small footprint 2" × 1", low overall height 0.9", dual layer PCB
• 100% surface mount construction
conversion applications
• Signature circuit is fully compatible with IEEE 802.3af requirements
• PWM controller and 220 V MOSFET switching device
• Accurate input voltage UV detection and OV protection
• Thermal, overload, short-circuit and open loop protection
• Regulation at zero load (cycle skipping)
• Accurate 400 kHz trimmed internal oscillator
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Engineering Prototype Report for EP-68 –
6.6 W DC-DC Flyback Converter Using
DPA-Switch
Power over Ethernet (PoE) Power Supply
Power Integrations Applications Department
EPR-68
19-Jul-2005
1.1
Tel: +1 408 414 9200 Fax: +1 408 414 9201
Power Integrations
www.powerint.com
(DPA423G)

Related parts for DAK-68A

DAK-68A 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

... VDC Maximum and Nominal Load ...............................................................22 12.2 57 VDC Maximum Load ....................................................................................23 13 Revision History ........................................................................................................24 Important Note: Although this board is designed to satisfy safety telecom isolation requirements, this engineering prototype has not been agency approved. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Table Of Contents Page ...

Page 3

... VoIP DC-DC converter applications. This report contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit board layout, and performance data. Figure 1 - EP68 Populated Circuit Board Photograph. Page Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 4

... Output Voltage Output Ripple Voltage Continuous Output Current Peak Output Current Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Safety Isolation Ambient Temperature Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Symbol Min Typ Max ...

Page 5

... Schematic *All resistors and capacitors are 0805 size unless otherwise specified Page Figure 2 - EP68 Schematic. Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 6

... Low ESR tantalum output capacitors, C7-9, reduce switching ripple and minimize losses. Secondary output choke L1 and ceramic output capacitor C10 reduce high frequency noise and ripple at the output. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Resistors R2 and R3 provide ...

Page 7

... Capacitor C12 provides a soft-finish characteristic, preventing output voltage overshoot during startup of the converter. 5 PCB Layout Figure 3 - Top Side, SMT Printed Circuit Layout (Top View). Figure 4 - Bottom Side, SMT Printed Circuit Layout (Top View). Page Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 8

... ERJ-6ENF3402V 34.0 kΩ, 1% ERJ-6ENF2002V 20.0 kΩ, 1% ER14.5 Transformer LSTA30825 SIL6029 IM 040 202 31 27V, 500 mW, SOD123 BZT52C27-7 15V, 200 mW, SOD323 BZT52C15S-7 150V TVS SMAJ150A Manufacturer Power Integrations Sharp Catalyst Semiconductor UCC Panasonic AVX Panasonic Panasonic Kemet Panasonic Panasonic Panasonic Vishay generic Zierick ...

Page 9

... Pins 1-3, all other windings open Pins 1-3, with Pins 6/7-9/10 shorted Description Tel: +1 408 414 9200 Fax: +1 408 414 9201 9,10 WDG #3 2T #28 AWG x2 6,7 4 WDG #2 8T #34 AWG 5 1500 VDC 120 µH, +/-10% 7.5 MHz (min.) 3.0 µH (max.) 2 Power Integrations www.powerint.com ...

Page 10

... Use one layer of item [5] for basic insulation. Outer Insulation Assemble and secure (glue or clamp, item[6]) core halves. Final Assembly Dip varnish item [7] and cure. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 6 - Transformer Build Diagram. Tape 1/2 Primary ...

Page 11

... Transformer Spreadsheet Page Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 12

... Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page ...

Page 13

... Figure 7 - Efficiency vs Output Load, Room Temperature. Page Efficiency Vs. Output Load 1.00 1.25 1.50 Load Current (A) Tel: +1 408 414 9200 Fax: +1 408 414 9201 VIN=36 VDC VIN=48 VDC VIN=57 VDC 1.75 2.00 Power Integrations www.powerint.com ...

Page 14

... Figure 8 9.2.2 Line 3.40 3.35 3.30 3.25 3.20 30.0 Figure 9 - Line Regulation, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Load Regulation 0.5 0.8 1.0 1.3 Load Current (A) - Load Regulation, Room Temperature. Line Regulation 40 ...

Page 15

... Figure 11 – 36 VDC, Full Load. Upper 0 div. DRAIN , µs / div. Lower: V DRAIN Page Maximum Output Current 40.0 50.0 Input Voltage (VDC) Figure 12 – 57 VDC, Full Load. Upper: I Lower: V Tel: +1 408 414 9200 Fax: +1 408 414 9201 60 div. DRAIN , µs / div. DRAIN Power Integrations www.powerint.com ...

Page 16

... Drain Voltage and Current Start-Up Profile Figure 15 – 36 VDC Input Resistive Load. Upper 0 div. DRAIN Lower 100 div. DRAIN Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 14 - Start-Up Profile, 57 VDC, No Load (worst-case). Upper div. OUT Lower div ...

Page 17

... Top: Load Current div. Bottom: Output Voltage, 20 mV, 500 µs / div. Page Figure 18 - Transient Response, 57 VDC, 75-100-75% Load Step. Top: Load Current div. Bottom: Output Voltage, 20 mV, 500 µs / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 18

... Figure 19 - Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed). Figure 20 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with Wires for Probe Ground for Ripple Measurement, and Two Parallel Decoupling Capacitors Added). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 19

... Figure 23 - Ripple, 57 VDC, Full Load. Top div, 50 µs / div. Bottom div, 2 µs / div. Page EP68 3 DC-DC Power Supply Figure 22 - Ripple, 48 VDC, Full Load. Top div, 50 µs / div. Bottom div, 2 µs / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 20

... Figure infrared thermograph taken at nominal-line (48 VDC). Ambient DPA423G (U1) Transformer core (T1) Output Rectifier (D1) Output Capacitor (C7) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ° Measured Temperature ( C) Item 36 VDC 48 VDC 57 VDC ...

Page 21

... Figure 24- Infrared Thermograph of the EP68 Board, 48 VDC, Full Load, Room Ambient. Page TOP VIEW BOTTOM VIEW Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 22

... Vertical Scale: Gain = div, Phase = 30° / div. Crossover Frequency = 10.0 kHz, Phase Margin = 60° Figure 26 - Gain-Phase Plot, 36 VDC, Light Load (100 mA). Vertical Scale: Gain = div, Phase = 30° / div. Crossover Frequency = 0.9 kHz, Phase Margin = 65° Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page ...

Page 23

... Figure 28 - Gain-Phase Plot, 57 VDC, Light Load (100 mA). Vertical Scale: Gain = div, Phase = 30° / div. Crossover Frequency = 0.9 kHz, Phase Margin = 60° The results indicate adequate loop bandwidth and significant gain and phase margin. Page Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 24

... Revision History Date Author 25-Feb-04 SH 02-Mar-04 PV 15-Mar-04 PV 19-Jul-05 PV Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Revision Description & changes 0.1 First release 0.2 Second release after minor edits 1.0 Final release 1.1 Fixed schematic and bill of materials (BOM) ...

Page 25

... Page Notes Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 26

... Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Notes Page ...

Page 27

... Page Notes Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 28

... 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 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 ...

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