DAK-86 Power Integrations, DAK-86 Datasheet

KIT REF DES DPA 6.6W DC-DC CONV

DAK-86

Manufacturer Part Number
DAK-86
Description
KIT REF DES DPA 6.6W DC-DC CONV
Manufacturer
Power Integrations
Series
DPA-Switch®r
Datasheets

Specifications of DAK-86

Main Purpose
Special Purpose DC/DC, Power Over Ethernet
Outputs And Type
1, Isolated
Power - Output
6.6W
Voltage - Output
3.3V
Current - Output
2A
Voltage - Input
33 ~ 57V
Regulator Topology
Flyback
Frequency - Switching
400kHz
Board Type
Fully Populated
Utilized Ic / Part
DPA423, DPA424, DPA425
Lead Free Status / RoHS Status
Not applicable / Not applicable
Other names
596-1195
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 Input: 33-57 VDC, Output: 3.3 V / 2.0 A
Application
Author
Document
Number
Date
Revision
Summary and Features
• Meets IEEE802.3af requirements according to University of New Hampshire
• DPA-Switch PWM controller with integrated 220 V power MOSFET switch
• Small footprint 3.1" × 1", low overall height 0.45" (excluding RJ-45 connector)
Interoperability Consortium (UNH-IOC) test results, for Class 1–3 PoE PDs
• Under-voltage (UV) and overvoltage (OV) shutdown functions
• Auto-recovering, hysteretic thermal shutdown
• Auto-restart function: protects against short-circuit and open loop faults
• No-load regulation achieved by cycle skipping
• Fully integrated soft-start minimizes start-up stress and overshoot
• Externally programmed I
• Lossless MOSFET current sense eliminates external sensing components
Engineering Prototype Report for EP-86 –
6.6 W Multi-Class Powered Device (PD) for
Power over Ethernet (PoE) Using
DPA-Switch
PoE Class 2 PD – Including IEEE802.3af
Compliant Interface Circuit
Power Integrations Applications Department
EPR-86
April 13, 2006
1.1
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
Power Integrations
www.powerint.com
LIMIT
®
scales with V
(DPA423G)
IN
for power limiting

Related parts for DAK-86

DAK-86 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 Ripple Measurements.....................................................................23 11 Revision History ....................................................................................................24 Important Note: Although this board was designed to satisfy safety isolation requirements, it has not been agency approved. Therefore, please take the appropriate safety precautions. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page ...

Page 3

... Data and test results that document the performance of the supply under various line and load conditions are also included. Figure 1 – Populated Circuit Board Top View. Figure 2 – Populated Circuit Board Bottom View. Page Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 4

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

Page 5

... Schematic Page Figure 3 – Schematic. Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 6

... MOSFET switch. Resistor R10 sets the gain of U4, while R11 and C13 compensate for the variation in gain of U4 over the frequency range of the feedback loop’s bandwidth (about 10 kHz). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 7

... Q7. The value of the classification current source is determined by the value of the voltage on the reference pin of U6 divided by the value of R20 in ohms. Page Figure 4 – Detection Impedance V-I curve. Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 8

... VDC. Resistors R15 and R16 form a voltage divider that turns off the base of Q2, once the DC-DC converter has begun switching and the bias voltage is present. At start-up, when the bias voltage is absent, Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 9

... VDC typical. However, because Q2 turns off after start-up, the UV turn-off threshold stays at 34 VDC (see DI- 101 for more details). Figure 7 – L-pin current without and with the widened UV hysteresis circuit. Page Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 10

... W, Metal Film, 0603 28 1 R11 1 kΩ, 5%, 1/10 W, Metal Film, 0603 29 1 R12 33.2 kΩ, 1%, 1/8 W, Metal Film, 0805 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Description Mfg Part Number ECJ-4YB2A474K 06031A470JAT2A 1808SC102KAT1A ECJ-1VB1E104K T495X337K006AS ...

Page 11

... Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic B.I Technologies Coilcraft Hical LiShin Santronics Ying Chin Power Integrations National Semiconductor Sharp National Semiconductor Diodes, Inc Diodes, Inc Panasonic-SSG Diodes Inc ...

Page 12

... Layout Figure 8 – PCB Layout Top Side. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 9 – PCB Layout Bottom Side. Page ...

Page 13

... Bobbin Page DPASwitch_Flyback_071405 - Continuous/Discontinuous INPUT INFO OUTPUT UNITS mode Spreadsheet. Copyright 2005 Power Integrations DC-DC Converter 36 Volts Minimum DC Input Voltage 57 Volts Maximum DC Input Voltage 3.3 Volts Output Voltage (main) Verify temperature rise for continuous power. P and G 6.6 Watts packages may be thermally limited Comment 0 ...

Page 14

... VD_OUT2 N_OUT2 PIV_OUT2 V_OUT3 VD_OUT3 N_OUT3 PIV_OUT3 I_OUT2 I_OUT3 Negative Output Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Maximum Duty Cycle 0.52 0.23 Amps Average Primary Current Peak Primary Current 0.64 Amps 0.40 Amps Primary Ripple Current ...

Page 15

... Pins 1-3, all other windings open 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 6,7 1500 VDC 120 µH, ±10% 7.5 MHz (Min.) 3.0 µH (Max 312 nH/T LG Power Integrations www.powerint.com ...

Page 16

... Use one layer of item [5] for basic insulation. Outer Wrap 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 11 – Transformer Build Diagram. Tape ...

Page 17

... Input and output voltages and current were measured with dedicated digital multi-meters (DMMs). 9.1 Efficiency 80% 70% 60% 50% 40% 0 Figure 12 Page Pout (W) – Efficiency vs. Line and Load, Room Temperature. Tel: +1 408 414 9200 Fax: +1 408 414 9201 36 VDC 48 VDC 57 VDC 6 8 Power Integrations www.powerint.com ...

Page 18

... Figure 13 9.3 Line Regulation 105.0% 102.5% 100.0% 97.5% 95.0% 30 Figure 14 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 3V3 36 VDC 3V3 57 VAC Pout (W) – Load Regulation, Room Temperature Vin (VDC) – Line Regulation, Room Temperature. ...

Page 19

... Performance was measured for various values of resistor R6. 4.0 3.0 2.0 1.0 0.0 30 – Overload Output Current vs. Line Voltage for Different Values of R6, Figure 15 Page 3 10.0 kΩ 3 10.2 kΩ 3 10.5 kΩ 3 8.66 kΩ Vin (VDC) Room Temperature. Tel: +1 408 414 9200 Fax: +1 408 414 9201 60 Power Integrations www.powerint.com ...

Page 20

... Output Voltage Start-Up Profile Figure 18 – Start-Up Profile, 36 VDC, No Load (worst-case). Upper div. OUT , µs / div. Lower: V DRAIN Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 17 – 57 VDC, Full Load. Upper 0 div. DRAIN , µs / div. Lower: V DRAIN Figure 19 – ...

Page 21

... Page The oscilloscope was triggered using the load current Figure 21 – Transient Response, 57 VDC, 75-100-75% Load Step. Upper: Load Current div. Lower: Output Voltage, 20 mV, 500 µs / div. Tel: +1 408 414 9200 Fax: +1 408 414 9201 Power Integrations www.powerint.com ...

Page 22

... Figure 22 – Oscilloscope Probe Prepared for Ripple Measurement (End cap and ground lead removed). Figure 23 – 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, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ...

Page 23

... Figure 26 – Ripple, 57 VDC, Full Load. Upper: 50 µs / div div. Lower: 2 µs / div div. Page Figure 25 – Ripple, 48 VDC, Full Load. Upper: 50 µs / div div. Lower: 2 µs / div div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 13-Apr-2006 ...

Page 24

... Revision History Date Author January 3, 2006 RM/LN/ME April 13 2006 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Revision Description & changes 1.0 RM 1.1 Updated photo, layout, schematic and BOM Initial release Page ...

Page 25

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

Page 26

... Power Integrations, Inc. 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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