User Manual 4-5-6
Contents
1. I Output Impedance and Audiosusceptibility I Input Filter Design and Analysis MEASUREMENT INTERFACE I import Measurements from AP200 or AP300 Analyzer id Fig 2 1 POWER 4 5 6 Guide Page with Start Menu POWER 4 5 6 has a wealth of features for design If you are just getting started do not check any of the boxes for now You can add more options for design and analysis later Click OK and you will be taken to the schematic page to begin your design and analysis TWIIPOWER 4 5 6 Manual 2 1 Entering Specifications and Topology Most of the time you will be working on the schematics page as shown below This will let you see waveforms and small signal measurements while interactively changing power parts and control parts An automatic expert system design routine will help you with all component choices If you are a new designer you may choose to let POWER 4 5 6 choose every parameter for you and you can expect a good working design On the schematic page you will see a power topology a buck converter in the figure below a controller with all the setting needed to implement most constant frequency options and a feedback compensator Of course the compensator and controller may all be in one chip but you have full control of all of the parameters Schematic components in red are clickable and you can edit their values and see components stresses This will be demonstrated in more detail later First though you will2. Copyright 1991 2015 Ridley Engineering Incorporated POWER 4 5 6 is copyrighted material Unauthorized copies of the software and manual may not be made Your copy of POWER 4 5 6 may be used by you on one machine only and not distributed to others Any modified or enhanced versions of POWER 4 5 6 are also protected by this copyright notice Full details of copyright notice are provided on software package For more information contact Ridley Engineering 3547 53 Av West 347 Bradenton FL 34210 E Mail rridley ridleyengineering com http www ridleyengineering com HIPOWER 4 5 6 Manual Table of Contents Page Number 1 Introduction to POWER 4 5 6 3 1 1 Computer System Requirements PC Based 5 1 2 Computer System Requirements MAC Based 5 1 3 POWER 4 5 6 Software Download 5 1 4 POWER 4 5 6 Software Installation 6 1 5 POWER 4 5 6 Software Upgrade 7 1 6 Loading Workbooks 7 1 7 Saving Workbooks 8 1 8 Saving Data Only and Transferring to New Version 8 1 9 Saving Data Only to run PSIM 9 1 10 Which Version Do have 9 1 11 Help Notes 10 1 12 Customer Support 10 1 13 Linkedin Support Groups 10 2 Simulation with POWER 4 5 6 11 2 1 Entering Specifications and Topology 12 2 2 Running Waveform Simulations 15 2 3 Startup Simulation 17 2 4 Step Load Transient Simulation 19 2 5 AC Input Simulation 20 2 6 Exploring Further Simulation Options 21 3 Control Analysis Transfer Functions 22 3 1 Turning On Control Options 22 3 2 Voltag
3. Once you have a license for the software all upgrades are free as long as your license is current Please contact us to let us know what you would like to see included in the program in the future We are constantly upgrading the software to respond to user s needs Once you have a license for the software all upgrades are free as long as your license is current ZIIPOWER 4 5 6 Manual Control Analysis Transfer Functions POWER 4 5 6 has unsurpassed techniques for designing and analyzing the control system for a switching power supply The analysis techniques and design routines have evolved over a period of 25 years to give you all of the control information that you need to optimize the performance of your power supply 3 1 Turning On Control Options When you click on the Control Design blue button you will see the green options buttons below appear on the power stage schematic If you don t see the Z Out and the Audiosusceptibility buttons make sure these features are checked when you click on the Features button Features Audiosusceptibility Specifications Topology Design Sequence Waveforms CONTROL Control Design Efficiency Feedback Design PWM Controller Fig 3 1 Control Design Options in POWER 4 5 6 Once you see the green control buttons click on the Loop button to see the main control transfer functions 22IPOWER 4 5 6 Manual 3 2 Current Mode and Voltage Mode Contro
4. PC Based To run POWER 4 5 6 effectively any modern computer with at least Excel 2007 or later installed will work The Power 4 5 6 code is extremely efficient and it does not need a high powered computer It is also very compact taking up only 15 MB of disk space Make sure you select the 32 bit version of Excel when installing Microsoft installs this by default and they do not recommend using the 64 bit version of Excel since it is missing many features and add ins POWER 4 5 6 will work with Windows XP Windows 7 or Windows 8 1 2 Computer System Requirements MAC Based Microsoft Office is available to run on the MAC but Excel does not work properly You will be able load POWER 4 5 6 but the formatting will not show everything properly In order to use POWER 4 5 6 on the MAC you will need to install a Windows partition and the normal PC based version of Excel 32 bit Microsoft recommends the use of the 32 bit version of Excel rather than the 64 bit 1 3 POWER 4 5 6 Software Download The latest version of POWER 4 5 6 is available for download at http ridleyengineering com index php software download software html If you are installing for the first time you should download the full install version and if you are upgrading download the update version In order to download the software you will need a software product key which looks like POWER456R91 XXXX XXXX XX 5IPOWER 4 5 6 Manual 1 4 POWER 4 5 6 Software
5. Power stage loss and stress analysis for all major components Output impedance analysis Audiosusceptibility Second stage LC filter analysis Snubber design and analysis Switching loss analysis for power FETs and IGBTs Control design and analysis on a single power stage schematic Toroid inductors with Micrometals parts POWER 4 5 6 is an Excel based program with interactive controls designed for rugged and reliable operation All of the features listed above are offered using clear schematic presentation of circuits and designs with pop up menus for easy data entry and analysis Extensive on line help is available at the click of a button Z3IPOWER 4 5 6 Manual There are three levels of application for this software These levels are commensurate with experience and stage of your design to help you achieve the greatest value from POWER 4 5 6 without the burden of knowing the equations involved in arriving at the solution We have defined these levels as follows Level 1 Basic Design At this level you can simply input the power requirements for your circuit When you click OK the entire converter including control loop is designed for you The components are chosen for you based on your data and these are working values which you can put into hardware with confidence Level 2 Intermediate Design Level two designers have design experience and want to input their knowledge as the design progresses They want to underst
6. 758 You will receive this error when your license has reached its expiration date Contact us to verify the date or to renew your registration Protection Error 923 Installation Incomplete CopyMinder protection error 923 OK You will receive this error if the software installation did not finish generating all of the necessary files Please go to Section 1 4 item number 2 of this manual to learn how to complete the installation 35IPOWER 4 5 6 Manual Trouble Closing POWER 4 5 6 BoostRelease9 Password Very rarely you may see this screen pop up when you try to close the program Clicking OK or Cancel will not get rid of it If this happens type ctl alt delete and select Start Task Manager Select Processes highlight EXCEL EXE 32 and click on End Process This should close the program WINWORD E RayRay2 00 175 192K Microsoft EXCEL EXE 32 RayRa 145 824K Microsoft j wimail exe 32 RayRay2 91 856K Windows Skype exe 32 RayRay2 63 400K Skype mspaint exe RayRay2 58 520K Paint explorer exe RayRay2 29 064K dwm exe RayRay2 26 100 K wicomm exe 32 RayRay2 6 596 K ControiDeck e RayRay2 5 788 K AsusWSServic RayRay2 5 356 K nis exe 32 RayRay2 4 536 K taskmagr exe RayRay2 3 844K taskhost exe RayRay2 3 156 K Boingo WiFi RayRay2 2 720 K WDDMStatus RayRay2 2 544K 00 00 00 00 00 00 00 00 00 00 00 00 00 00 Processes 102 CPU Usage 0 36IPOWER 4 5 6 Manual
7. is run to confirm that the converter is operating properly To begin doing this click on the blue button labeled Waveforms then click on the scope probe at the output of the converter as shown above 15IPOWER 4 5 6 Manual POWER 5 1 Output Voltage V Horizontal Delay Step Time Base e 7 Min Vertical uF A W RESET Startup Continue Steady State c nducto m a AE Line and Load Conditions C ti Show Voltage and Current ompensation Fig 2 6 POWER 4 5 6 Output Voltage Waveform Figure 2 6 shows simulation of the output voltage for 400 cycles To zoom in on this waveform treat the controls of POWER 4 5 6 just like a scope Turn the time base dial clockwise to zoom in by clicking on the up arrow next to the dial as shown below POWER 5 Output Voltage V Horizontal Delay ANH 3 CLICK e 4 HAHAE Startup Continue Steady State Line and Load Conditions C ti Show Voltage and Current ompensation Fig 2 7 POWER 4 5 6 Expanded Output Voltage Waveform Each time you click on the up arrow the number of complete waveforms will be cut in half You can quickly turn the dial back to the original setting by clicking on the Min setting 16IPOWER 4 5 6 Manual Output Voltage V Fix Vertical Autoscale 2 uF AV Reser up Continue Steady State Cc ucto 8 54 pH iv RESET Line and Load Conditions Fig 2 8 POWER 4 5 6 Start Up Simulation Voltage Waveform Startup of your converter can
8. want to enter your particular specification for your power system The blue buttons on the page will enable different forms and options for design To enter your power specifications click on the top blue button as shown below Features Specifications Topology Design Sequence Waveforms Control Design Efficiency Soft Start T PWM Controller Fig 2 2 POWER 4 5 6 Schematic Page 12IPOWER 4 5 6 Manual x POWER 4 5 6 Demo Version Clear Design m INPUT VOLTAGE RANGE DC Input 120 VAC 240 VAC 120 240 VAC Low Line Voltage 5V fixed for demo Nominal Input Voltage 7V fixed for demo High Line Voltage 12V fixed for demo m OUTPUT VOLTAGE AND CURRENT Main Aux 1 Aux 2 Aux 3 Aux 4 li SECTS RIS ESA Output Voltage and Current Fixed for Demo Version Output Current 10A POWER SUPPLY COOLING High Airflow Moderate Low Airflow None 25 FEEDBACK CONFIGURATION Soft Start Non Isolated TL431 Opto TL431 Opto Bias T PWM Controller Fig 2 3 POWER 4 5 6 Specifications Entry Form The first area of the Specifications form lets you choose either DC or AC input For the demo version AC input is disabled and the dc input range is set to 5 12 V In the full version you can enter both AC and DC options and select the input voltage range as you wish In the demo s
9. will load data from the TRANSFER xlsm file into your POWER 4 5 6 worksheet Export Specifications and Design Data sS Save Data ort import Data Topology Design Sequence Import Specifications and Design Data Waveforms If you have an older version than 9 56 and you wish to upgrade and transfer your data this can also be done Open your older version of POWER 4 5 6 for example POWER456R951 xlsm Then open the file TRANSFER xIsm go to the Power Stage design page of POWER 4 5 6 and enter Alt F8 to select macros In the box Macros in select Transfer xlsm select the macro transfer xlsm xfersave and hit Run This will save your data in the Transfer worksheet You can then open the latest version of POWER 4 5 6 and follow the process above to reload your data into the new version BIPOWER 4 5 6 Manual 1 9 Saving Data Only to Run PSIM POWER 4 5 6 can now be linked to the simulation program PSIM to allow you to run general circuit simulations and modify the schematics To take advantage of this feature it is necessary to have two files open POWER456R956 xlsm and ExportPSIM xlsm Once you have opened these files go to the Power Stage page of POWER 4 5 6 and click on the Export Import Data button When you then click the Export button your data that you have entered will be placed in the ExportPSIM xlsm file 1 10 Which Version Do I Have Release August 7 2014 Nyquist plot added This can be overlaid on t
10. 4 5 6 while adjusting the pole and zero locations of the compensation as shown in the figure above Each time you click the button the zero or pole will be moved new compensation components selected and the curves replotted Output Voltage V Compensation Zeros FirstZero 26 za Hz Default P Compensation Poles Second Pole Hz Hz Default Bid IESE l Startup Continue Steady State Line and Load Conditions Fig 3 5 Interactive Adjustment of Compensation Poles and Zeros with Simulation Waveforms You can also interactively change the compensation parameters while looking at the simulation waveforms This is a powerful feature with POWER 4 5 6 and the simulation speed is essential for optimizing your control this way 25IPOWER 4 5 6 Manual 3 4 Voltage Feedforward Control Fixed Ramp Height i FEEDFORWARD VOLTAGE FEEDFORWARD RAMP PARAMETERS Input Voltage Divider 15 vN 45 V V_ Default 6 Maximum Ramp Height Vat 90 V Input Minimum Ramp Height 0 666 Vat 10 V Input j V PWM Ramp Height Fig 3 5 Selecting Voltage Mode with Feedforward Starting with Release 9 60 of POWER 4 5 6 it is possible to implement voltage mode control with feedforward The normal implementation of this technique in the control chip is to make the control ramp proportional to the input voltage scaled by an input voltage divider constant k When the input voltage is increased the ramp size w
11. 4s m mE POWER SUPPLY COOLING High Airflow Moderate Low Airflow None 25 al Soft Start I PWM Controller Fig 2 12 Choosing AC Input on the Specifications Form not available in Demo Version 2Z0IPOWER 4 5 6 Manual nput Voltage Vrms Hz Fullwave Rectifier Halfwave Rectifier Input Capacitance 59 1 Capacitor ESR 203 mo Present Simulated Load AC Line Current Capacitor Current Dissipation Minimum Voltage Key p VALU E Use Minimum Value for Design 0 060 Fig 2 13 AC Input Waveforms for a 27 W Flyback Converter not available in Demo Version The simulation of input line current and input capacitor voltage are shown in the figure above 2 6 Exploring Further Simulation Options Many more simulation options are possible within POWER 4 5 6 and you are encouraged to try them For example with the transient load simulation in Fig 2 11 you can interactively see the change in transient performance with different value inductors and capacitors You can move these values up and down while watching the change in the waveforms This is a truly unique feature of POWER 4 5 6 that will change the way that you do your designs and greatly speed up the process You are encouraged to try all these options in POWER 4 5 6 Let us know what you see and tell us if there are additional features of that you would like to see included in the program in the future
12. 51 nH n2 Inner Turn Length Outer Turn a Fig 4 3 Inductor Core and Turns Selection Pushing the top button on the inductor design page will bring up the form for selecting the design parameters of the inductor By default a generic core will be selected with a recommended core area This lets you choose any specific core that you or your company likes to use that has approximately that area A larger core area will run a little cooler and a smaller core size will have higher dissipation Your actual selection will depend on your cooling situation and your need for efficiency versus size If you click on the Select Core button you will be presented with an array of standard cores to use and you can also add your own favorite cores very easily to the program 2QIPOWER 4 5 6 Manual 4 4 Choosing the Inductor Core Material Turns Core and Gap Core Materials and Loss by Manufacturer Materi al Make sure the converter simulation has reached steady state before calculating core and winding losses Operating Delta 0 057 T Maximum Flux 0 213 T Ninding Micrometals in order of increasing permeability Magnetic F 0457 W 0 269 2 not available 60 not available 14 not available 40 not available 0 162 W 30 not available 26 not available Fanuc 34 not available 52 not available f 0 589 w 35 not available 38 not available 1 006 W 8 not available 45 no
13. Decimal Separator Problem Run Time Error 1004 Input and Output Specifications i a ss Unable to set the Text property of the Characters dass Continue Debug Help Main Aux 1 Aux 2 Aux 3 Aux 4 Output Voltage 09 O a m POWER SUPPLY COOLING High Airflow Moderate Low Airflow None This error will occur if you do not have the decimal separator character set to a period You can change the setting of the decimal separator in your Windows system as described below Click on Control Panel Region and Language Under the Format tab click on Additional Settings and you will be able to change the character to a period as shown 37IPOWER 4 5 6 Manual We HFSS Se a Ce Sa Rk TO GF gt Control Panel All Control Panel Items p Search Control Panel i Adjust your computer s settings is ana as i Action Center YW Backup and Restore E Credential Manager I Desktop Gadgets Positive 123 456 789 00 I Display a Fonts amp Indexing Options Decimal symbol 6 Java 32 bit No of digits after decimal Mail Microsoft Outlook 24 R E Network and Sharing Ceni Digit grouping Parental Controls Digit grouping Phone and Modem Negative sign symbol Realtek HD Audio Manag Negative number format I RemoteApp and Desktop Display leading zeros aog
14. IDLEY DISCLAIMS ANY IMPLIED WARRANTY OF FITNESS 42IPOWER 4 5 6 Manual LIMITATION OF LIABILITY DAMAGES LIMITATION Except for the remedies set forth in the Limited Warranty statement Ridley shall have no liability or obligation for any other damages or remedies including without limitation the cost of substitute goods and any direct incidental special or consequential damages arising out of this Software License and Limited Warranty statement or the use or inability to use the PROGRAMS Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you LIMITATION OF LIABILITY In no event shall Ridley s liability whether in contract warranty tort including negligence product liability or other theory with regard to the PROGRAMS the accompanying written materials or this Software License and Limited Warranty Statement exceed the compensation you paid to Ridley for the PROGRAMS If you wish to contact Ridley Engineering for any reason including warranty service please write to Ridley Engineering Inc Ridley Engineering Inc 3547 West 53 Avenue Suite 347 Bradenton Florida 34210 In Europe Ridley Engineering Europe UK Ltd Beech Court Unit 1 Wokingham Road Hurst RG10 ORQ EMail info ridleyengineering com 43IPOWER 4 5 6 Manual
15. Installation 1 You should have downloaded an executable file Setup exe on your computer Double click on this file to follow the installation procedure You will be prompted to give the name of the directory where you want the POWER 4 5 6 files to go 2 Inthe target directory you should see the following files when the installation program is done POWER456R9x xlsm Transfer xlsm ExportPSIM xlsm POWER456R91 dll POWER456R91 dll cm POWER456R91 dll cm ini CMInstall exe The filename in blue with the extension xlsm is the main POWER 4 5 6 program which will run under Excel The three files shown in green contain the permission code to work with your specific password for the program provided to you when you purchased POWER 4 5 6 If you do not see the last of the three green files in your directory the software will not be allowed to run In this case right click on the filename shown in red and select Run As Administrator Answer OK to any questions and at the end of the process the third green file in the list above should appear in the directory 3 Double click on the blue file name to launch POWER 4 5 6 When the program begins to load you may get the message that it contains Macros Click Enable Macros The first time that you load POWER 4 5 6 there will be a registration process Please select one of the following options Configure as a standalone program Configure as a trial C Configure as a network client Please e
16. List rator Troubleshooting eee a Windows CardSpace Measurement system F Windows Mobility Center Standard digits Click Reset to restore the system default settings for numbers currency time and date Ca 38IPOWER 4 5 6 Manual Data Entry Format Error Run Time Error 13 nr Microsoft Visual Basic Run time error 13 Most mistakes in data entry will be flagged by POWER 4 5 6 and will give you an error message However if you see the message above you may have the decimal separator set incorrectly in your system This is changed as described in the above section If this does not fix the problem you can solve it by clearing your design but before you do that if you save the file and send it by email to us we can find the error This will help us capture the few remaining data entry problems 39IPOWER 4 5 6 Manual Microsoft Excel Stopped Working EMET problem Windows is checking for a solution to the problem If you get the message that Excel has stopped working while verifying the license it may be because your IT department has installed Microsoft EMET Enhanced Mitigation Experience Toolkit This will block access to the required website to verify the license code It is necessary to disable the following EMET options for POWER 4 5 6 to register itself properly without triggering EMET to shut down the program Export Address Table Filtering Simulate the execution flow There is no
17. Support Groups If you are a part of LinkedIn there is a group dedicated to POWER 4 5 6 support and upgrade notifications Whenever a new version of the software is available a posting will be placed on this site immediately notifying you You can also ask questions about the software at this site The group is called POWER 4 5 6 USERS GROUP and it can be found at https www linkedin com groups amp gid 4800268 Please also join our very active discussion group on LinkedIn with over 5400 power supply engineers POWER SUPPLY DESIGN CENTER and it can be found at https www linkedin com groups amp gid 4860717 1OIPOWER 4 5 6 Manual Simulation with POWER 4 5 6 POWER 4 5 6 has the fastest closed loop power supply simulator available It can accurately simulate 400 cycles of closed loop operation of a converter with almost instantaneous results There is no more tedious waiting for Spice to finish working on a simulation Change parameter values control design or power stage elements and see the results on true large signal waveforms instantly To begin you first simulation click on Start and you will see a menu as shown below BASIC DESIGN FEATURES Topology Selection Component Selection Controller Design Waveform Simulation Current Mode or Voltage Mode Control Automated Compensation Design Control Loop Analysis Stress and Loss Analysis ADVANCED DESIGN FEATURES I Magnetics Designer I Snubber Design and Analysis
18. and and further optimize their design At this level you will look carefully at the selected values from POWER 4 5 6 and change some of them to improve the design Level 3 Advanced Design Level three designers not only know how to design an effective power supply they know how to get maximum performance out of their power system for their very specific applications They have a library of preferred parts that work well for their applications and use these to fully optimize the design The magnetics design section works similarly in levels You can view the transformer or inductor on the main design schematic and 1 Choose from simplified parameters and refer to a magnetics design house for completion 2 Choose your own cores wire and other components and give the completed design to a manufacturer for production or 3 Design the magnetics from the ground up using your own parameters and knowledge Regardless of your design experience POWER 4 5 6 allows you to check and cross check all parameters and results You can stop at any time during the process and view resulting waveforms and control parameters We hope you enjoy the benefits of this interactive design tool To learn more about the powerful capabilities of the program we highly recommend attending one of our four day Power Supply Design Courses Details are found on our web site http www ridleyengineering com 4IPOWER 4 5 6 Manual 1 1 Computer System Requirements
19. be simulated by clicking the green button as shown above This will start with zero output voltage and zero inductor current and simulate the converter into regulation as shown It takes over 200 cycles to get the output voltage into regulation in the example shown It can be instructive to click on button to add the current waveform of the converter to show what effect the current limiting has on the performance of the startup ERAS Output Voltage V Inductor Current A Fix Vertical Autoscale c ac w AY RET Startup Continue Steady State C o 8 54 pH iv RESET Line and Load Conditions Fig 2 9 POWER 4 5 6 Start Up Simulation Voltage and Current Waveforms IJTIPOWER 4 5 6 Manual In the red waveform of Figure 2 9 you can see that the converter enters current limiting during startup and later on you can actually see subharmonic oscillation in the current sensing current limit is like current mode control with no ramp added and this slows down the rise of the output voltage Output Voltage V kHz Default 12 252 A Default S Controller Type Custom Controller Select IC Inductor Current A Duty Cycle Limit 0 93 Default e Reference Voltage 25 V Default Ve Max 2 75 V Default Gain After Error Amplifier 1 Default Fix Vertical Controller Dissipation 02 W Default Autoscale C Current Mode Control Voltage Mode Control PWM DUTY CYCLE RANGE Startup Continue Steady St Calculated Minimum Lineand Load Condition
20. blem 39 Object Doesn t Support Property or Method 40 33IPOWER 4 5 6 Manual Cannot find POWER456R91 DLL Cannot find POWER456R91 DLL This should be in the Windows System32 directory You will see this message if you try to run your POWER 4 5 6 file from a directory other than the original installation directory It s OK to save files to other directories but when you want to run them take them back to the original directory Do NOT try moving the dll files to the System32 directory this will not solve the problem Compile Error EXCEL 64 bit Installed Instead of 32 bit Excel Microsoft Visual Basic for Applications Compile error in hidden module ThisWorkbook This error commonly occurs when code is incompatible with the version platform or architecture of this application Click Help for information on how to correct this error You will see this message if you have 64 bit version of Excel installed on your computer This is not recommended by Microsoft since it is missing many features and add ins Please reinstall the 32 bit version of Excel This is the default installation 34IPOWER 4 5 6 Manual Protection Error 717 Incorrect Passkey Entered CopyMinder protection error 717 J You will see this message if you enter an invalid passkey for the program Check for the proper number and contact Ridley Engineering if you cannot find it Protection Error 758 License Expired CopyMinder protection error
21. button allows you to enable the magnetics design features of POWER 4 5 6 27IPOWER 4 5 6 Manual 4 2 Inductor Design Page Turns Core and Gap Clear Inductor Design Core Material Magnetics Test Setup Inductor Impedance s3 Az Fig 4 2 Inductor Design Page Guides You Through The Inductor Details Clicking the Inductor Design button on the Power Stage page will take you to the inductor design sheet in POWER 4 5 6 On this page pushing the blue buttons on the right will step you through a detailed design process This will include core selection material selection winding design proximity loss and many other details 28IPOWER 4 5 6 Manual 4 3 Choosing the Inductor Core Size Tums Cod Core Design INDUCTOR CORE SELECTION Approximate Core Area 0 7 sq cm Select Core C Use Selected Core CORE TYPE AND AREA Core Type Generic Inductance Minimum Area 0 7 sq cm MAXIMUM FLUX LEVEL SETTING 0 3 if ajv RESET This value will determine the number of turns needed Core Material INDUCTOR TURNS REQUIRED Maximum Flux Density at Peak Current Limit 0 2825 T Magnetics Test Setup m CORE PHYSICAL DETAILS CORE GAPPING Core Volume sot 181 mm 724 mills Inductor Impedance Window Width 1 25 Note that gap length is a rough guide only Manufacturing design is specified Window Build 0 41 by Al and the core is gapped to achieve the correct value 3 57 6 14610 cm Al value 48
22. ce and stability Loop gains will be plotted and analyzed Finally 400 cycles of large signal operation will be simulated All of this is done in a few hundred milliseconds You will find that this greatly speeds up and changes your entire design experience No longer will you have to wait ten minutes or so for Spice to predict waveforms every time you make a circuit change Your design procedure will become much more interactive trying far more options and repetitively simulating as if you had a live breadboard Before digging deeper into design values it is very valuable to look at circuit waveforms to see how the converter is operating At this point you have had no input to design values and POWER 4 5 6 will provide you with fully automated results for a realistic converter You can verify this by looking at the waveforms of the circuit 14IPOWER 4 5 6 Manual 2 2 Running Waveform Simulations Features CLICK 1 Specifications Topology Design Sequence Waveforms Control Design Efficiency Ve Max Soft Start T PWM Controller Fig 2 5 POWER 4 5 6 Waveform Choices Figure 2 5 shows the selection of voltages and currents that can be probed with POWER 4 5 6 The simulation algorithm inside POWER 4 5 6 is so fast that you will routinely run hundreds of simulations during a design session never having to wait for the results Every time a component is changed another 400 cycle simulation
23. e enclosed computer programs the PROGRAMS on a single computer in accordance with the terms of this Software License Ridley reserves all rights not expressly granted to you in this software license This license is effective until terminated Ridley may terminate this license if you fail to comply with this Software License In the event of such termination you agree to destroy the original and all copies of the PROGRAMS 2 Copyright The PROGRAMS are licensed not sold to you Ownership of the PROGRAMS and their associated proprietary rights are retained by Ridley and its assignees The PROGRAMS are protected by the copyright laws of the United States and other countries and by international treaties Therefore you must comply with such laws and treaties in your use of the PROGRAMS and among other things you may not copy the PROGRAMS except that you may load them into the random access memory of your computer install the PROGRAMS ona hard disk or other storage device of a single computer copy versions of the PROGRAMS as you modify their data contents onto a single computer and make a single copy for archival purposes Any copies of the PROGRAMS either in their original forms or modified by you are subject to this Software License You may not copy the written material accompanying the PROGRAMS without the prior written consent of Ridley 3 Transfer and Use Restrictions You may not sell lend or otherwise transfer or lease the PROGRAMS
24. e Mode and Current Mode Control 23 3 3 Interactive Compensation Adjustment 25 3 4 Voltage Feedforward Control 26 1IPOWER 4 5 6 Manual 4 Magnetics Design 27 4 1 Turning On Magnetics Options 27 4 2 Inductor Design Page 28 4 3 Choosing the Inductor Core Size 29 4 4 Choosing the Inductor Core Material 30 4 5 Inductor Winding Design 31 4 6 Transformer Design 31 Appendix A Error Messages 32 Appendix B License Agreement 42 2IPOWER 4 5 6 Manual Introduction to POWER 4 5 6 POWER 4 5 6 is the only switching power supply design program which provides component design large signal simulation feedback control design and small signal analysis in one easy to use package Features of POWER 4 5 6 Release 9 include Power stage designer Magnetics designer included in full version not in Control and Simulation version 9 topologies most commonly used in the industry plus rectifier options All topologies in one program allow you to compare quickly and easily Industry s fastest cycle by cycle simulation shows true large signal performance Control loop designer suitable for constant frequency PWM Current mode control using the latest and most accurate modeling techniques Voltage mode control using the results of the PWM switch model CCM and DCM converter simulation and analysis Small signal analysis of control system including loop gain Digital compensation delay and coefficient calculation Two stage input filter design and analysis
25. eyA p d Load Conditions ee oma Compensation Fig 2 11 POWER 4 5 6 Step Load Transient Simulation The line and load conditions can be set as shown above Two values of load are shown and the first 200 cycles are run with 100 load the second 200 cycles with 20 load Simulation of both the voltage and current are shown with the inductor current entering DCM on the second transient when the load falls to 20 19IPOWER 4 5 6 Manual 2 5 AC Input Simulation With the full version of POWER 4 5 6 you can select an AC input and perform a simulation of the input rectifier Three choices of range are available to you When you check one of these buttons as shown below the expected low nominal and high line voltages will be filled in for you You can change these values if you wish Once you have checked an AC input the schematic will change on the input showing you the input rectifier block After clicking OK click on the rectifier at the input to see the simulated input waveforms Features Specifications Clear Design 120 240VAC C DC Input RECTIFIER Topology Design Sequence Nominal Input Voltage 240 High Line Voltage 264 AC LINE FREQUENCY 50Hz C 60Hz f 400Hz C CustomFrequency 50 Hz Waveforms Control Design Efficiency OUTPUT VOLTAGE AND CURRENT Main Aux 1 Aux 2 Aux 3 Aux 4 Output Voltage 61 rT i Output Current
26. he loop gain to see the correlation Corrections to digital delay when user sets sampling frequency sion 9 49 Released August 7 2014 re is licensed for your use It remains the property of Ridley se help support us in our efforts to prevent illegal distribution When entering actual turns on the flyback transformer turns ratio and inductance are recalculated with the new specified turns ratio load resistor above 200 ohms ent ESR calculations 3 on output for high voltage applications 3 Fig 1 2 POWER 4 5 6 Version Number and Recent Updates To find out which version you have installed click on the Version button on the opening screen You can also see the recent changes and upgrades by clicking on the Updates button 9IPOWER 4 5 6 Manual 1 11 Help Notes POWER 4 5 6 has extensive on line help inside the program Click on any of the help buttons to access notes about a particular feature of POWER 4 5 6 A wealth of design information is contained in the program together with power supply design tips 1 12 Software Support If you are having problems installing or running POWER 4 5 6 please call or e mail for help If no one is immediately available please leave a message including your name and phone number and your call will be returned as soon as possible You can attach your file to an email for assistance Phone US 770 640 9024 E Mail rridley ridleyengineering com UK 44 0 1509 276 245 1 13 LinkedIn
27. ill increase and there will be an immediate change in duty cycle This can greatly improve the transient response with changes in input voltage Normally it will be at least an order of magnitude better especially for buck derived converters In addition the changing ramp will make sure that the loop gain of the system stays fixed for different input voltages This can be very important for large ranges of input voltage and compensation will remain optimal across the entire range The converter will regulate much better and step load response will be improved at low line 26IPOWER 4 5 6 Manual 4 Magnetics Designer 4 1 Turning on the Magnetics Designer Features Features Specifications M BASIC DESIGN FEATURES Topology Selection Topology Component Selection Controller Design Waveform Simulation Current Mode or Voltage Mode Control Automated Compensation Design Control Loop Analysis Stress and Loss Analysis Design Sequence Waveforms Control Design m ADVANCED DESIGN FEATUR Magnetics Efficiency IV Snubber Design and ANalysis J Second Stage Output Filter Design IV Output Impedance and Audiosusceptibility J Input Filter Design and Analysis M MEASUREMENT INTERFACE import Measurements from AP200 or AP300 Analyzer Fig 4 1 Selecting the Magnetics Design Option Enables the Inductor and Transformer Designers On the Power Stage design page clicking on the Features
28. it Exactly is Number of Layers 0 343 mm 0 343 Your Choice of Conductor Size mm Helical Foil mills 13 5 mills netics Test Setup m WINDING LOSS DETAILS uctor Impedance RMS Current 20 03247 A Winding Loss Including Proximity DC Current 19 98549 A Winding Loss without Proximity Loss AC Current 1 37114 A Winding Surface Area DC Resistance 2 99E 03 Q AC Resistance 1 63E 01 2 1 499 w w 1 198 6 83 sq cm be used in the converter simulation Fig 4 5 Inductor Winding Design Once you select OK values appearing on this form will Pushing the Winding button will show you the details of the inductor winging You can build inductors with foil helical windings or with wire and POWER 4 5 6 will help you to optimize each of these The foil winding thickness can be optimized with proper consideration for proximity losses by clicking the Minimize Loss button Details of the sophisticated techniques used to calculate the proximity loss are given in the Ridley Engineering Design Center www http www ridleyengineering com design center html in numerous papers on magnetics design and analysis 31IPOWER 4 5 6 Manual 4 6 Designing Transformers Turns and Core TRANSFORMER CORE SELECTION Core Material Approximate Core Area 1 048 sq cm Select Core C Use Selected Core m CORE TYPE AND AREA Core Ty
29. just individual worksheets TIPOWER 4 5 6 Manual 1 7 Saving Workbooks Your design in POWER 4 5 6 can be saved just like any Excel workbook It is recommended that you save a project under a different name from the original file To do this click on File Save As and specify a name for your project Every time you do this you will be saving a complete copy of POWER 4 5 6 together with the simulator designer and all the features of the program It is a live copy of your design constantly analyzing and simulating any changes you make not just the data You can save the design workshop in any directory you wish on your computer However please note that you must move a design workshop to the original POWER 4 5 6 directory to open it with the proper permissions working 1 8 Saving Data Only and Transferring Data to New Version Starting with Release 9 56 POWER456R956 it is possible to save just the data from your design This feature has been added to allow you to easily transition your design to a new version of the program without having to re enter all of your design choices To take advantage of this feature it is necessary to have two files open POWER456R956 xlsm and TRANSFER xlsm Once you have opened these files go to the Power Stage page of POWER 4 5 6 and click on the Export Import Data button When you then click the Export button your data that you have entered will be placed in the TRANSFER xIsm file Clicking on Import
30. l SELECT PLOTS Power Stage Details Loop Test Setup Compensation Fig 3 2 Current Mode Control Transfer Function Bode Plots in POWER 4 5 6 Figure 3 2 shows the control transfer functions which are available in POWER 4 5 6 You can select multiple plots to be shown all at the same time as shown in the box above Measurements from the AP300 Frequency Response Analyzer can also be overlaid on the graph to compare with predictions You can do many things on these graphs including moving the line and load up and down and changing the values of the inductor and capacitor in the converter As you change these values you can see the immediate effect on the power stage compensation and loop gain Note that when you change the inductor and capacitor values each time you click on the button the control loop is optimized for the new power stage and the transfer function plotted for the updated design 400 cycles of simulation are also run but this is fast enough that you won t even notice POWER 4 5 6 will automatically detect whether the converter is operating in CCM or DCM and provide the appropriate transfer function If you wish to see details of the converter you can click on the Power Stage Details button and it will give you the poles and zeros The Compensation button is a recent feature of POWER 4 5 6 that lets you interactively move the shape of the compensation values while looking at the shape of the loop at the same time Fig
31. nter your Product Key below A Product Key takes the form PO WER456R91 POCO POOK IX If pou don t have a Product Key please contact your software supplier POWE R456R91 L45B V 7GH 3R Cancel Help Select the file to be configured as a standalone program and enter the password which you should have received upon purchase After this you will be asked to enter registration information including address and contact information 6IPOWER 4 5 6 Manual 1 5 POWER 4 5 6 Software Upgrade If you have already installed POWER 4 5 6 select the upgrade version at http ridleyengineering com index php software download software html This is a zipped excel file and it should be unzipped and placed in the same directory as the previous version of the software that you had 1 6 Loading Workbooks After registration Excel will then proceed to open the specified workbook and a page like that shown in Fig 1 1 will appear on your screen after a few seconds Once you see this screen and the words License Verified in the bottom left corner your product is fully registered Fig 1 1 POWER 4 5 6 Guide Page The worksheets of POWER 4 5 6 are initially sized and formatted for an 1024x768 display For other resolution options click on the Screen Setup button and select options that fit your system The pages will fit optimally on the screen when you select the toolbars option You can also use the zoom slide bar at the bottom right to ad
32. oftware the output voltage is fixed with a 3 3 V 10 A setting Airflow and temperature ranges will impact magnetics design and the feedback can be configured with or without isolation Once you click OK on this form you will see a summary of your inputs to check then you will be presented with a set of choices for the topology of the power stage IZIPOWER 4 5 6 Manual Features Specifications Topology Boost not possible z Design Sequence Waveforms Single Switch Forward Two Switch Forward Half Bridge Control Desai g ontrol Design lk Tos i Efficienc Fa Tl f E f y l i t HaltWave C Full Wave Use Voltage Mode Only Full Bridge Push Pull Flyback H j i f J i t TF aRoperation Half Wave C Full Wave J Allow DCM Only RCDClamp Half Wave Full Wave Eg Fig 2 4 POWER 4 5 6 Topology Choices Figure 2 4 shows the set of topologies available for the input and output voltage specifications Notice that the boost topology is not possible since the output voltage is lower than part of the input range of the converter To follow along with this guide select the buck converter by clicking on the area shown above Once you have done this POWER 4 5 6 will proceed to do an amazing amount of work First all the power components will be selected A controller will then be optimized around the power stage to give good transient performan
33. or this license to others without written permission from Ridley LIMITED WARRANTY STATEMENT 90 Day Limited Warranty Ridley warrants that the PROGRAMS will perform substantially as provided in the accompanying written materials for a period of ninety 90 days from the date of receipt from Ridley This Limited Warranty gives you specific legal rights and you may have other rights which vary from state to state and from country to country Remedies Ridley s entire liability and your exclusive remedy for any failure of the PROGRAMS to comply with the Limited Warranty shall be at Ridley s option a repair or replacement of the PROGRAMS or b return of the price you paid for the PROGRAMS You must return all copies of the PROGRAMS and written material to Ridley or Ridley s dealer with a written explanation of the noncompliance and a copy of your receipt within 90 days of the date you received the PROGRAMS to receive this remedy Any replacement PROGRAMS will be warranted for the remainder of the original 90 day warranty period or 30 days from the date you received the replacements whichever is longer DISCLAIMER OF WARRANTIES Ridley does not warrant that the programs are free from all bugs errors and omissions Except for the 90 Day Limited Warranty described above Ridley makes no other warranties express or implied with respect to the PROGRAMS and any accompanying material RIDLEY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY AND R
34. pe Generic Minimum Area 1 048 sq cm MAXIMUM FLUX LEVEL SETTING DOE This value will determine the number of turns needed rimary Winding condary Winding TRANSFORMER TURNS d Secondary Turns 6 711409 0 2764 mH jnetics Test Setup Magnetizing Inductance Worst Case Flux Density 0 2838 T Maximum input Voltage and Maximum Duty imary Impedance CORE PHYSICAL DETAILS Core Volume 6 43 cu cm Window Width 1 53 cm Window Build 0 511 cm Inner Turn Length 4 285 cm Outer Turn 8 37 cm Hel Once you select OK values appearing on this form will OK P be used in the converter simulation Fig 4 6 Transformer Design Page POWER 4 5 6 has a powerful program for designing transformers incorporating advanced core loss calculation proximity loss analysis core and winding selection all in an easy to use package The design program interfaces closely with simulation waveforms to provide fast efficient and reliable designs 32IPOWER 4 5 6 Manual Appendix A Error Messages Error Message Page Number Cannot find POWER456R91 DLL 33 Compile Error 64 bit EXCEL Installed Instead of 32 bit Excel 33 Protection Error 717 Incorrect Passkey Entered 33 Protection Error 758 License Expired 34 Protection Error 923 34 Trouble Closing POWER 4 5 6 35 Decimal Separator Problem Run Time Error 1004 36 Data Entry Format Error Run Time Error 13 38 Microsoft Excel Stopped Working EMET pro
35. s Calculated Maximum Present Simulation CONTROLLER Fig 2 10 POWER 4 5 6 Start Up Simulation with Increased Current Limit If you click on the controller part of the schematic below the simulation as shown above you can pull up the form to change controller parameters In the case shown the current limit is raised from 12 25 A to 15 A This relatively small change in peak current limiting eliminates the subharmonic oscillation and the converter reaches regulation much more quickly Once you click on OK the new simulation will run and you can immediately see the changes in performance Determining the proper values of parameters such as current limit is absolutely crucial at the very early stages of design The peak current will impact the design of magnetics and sense resistors and you don t want to discover this kind of effect later on in the design cycle POWER 4 5 6 is ideal for this kind of work since it automatically designs all compensation parameters at the very beginning of a design and this is essential for proper simulation ISIPOWER 4 5 6 Manual 2 4 Step Load Transient Simulation Output Voltage V Inductor Current A INPUT VOLTAGE Initial Input Stepped Input OUTPUT POWER Initial Power Stepped Power 20 Rate of change Note Step values of line and load will occur midway through the simulation time VY RESET Sta Continue Steady State LINE AND i
36. security risk in implementing these changes 40IPOWER 4 5 6 Manual Object Doesn t Support Property or Method You may see messages such as this when you click on one of the buttons Microsoft did some security updates recently and it causes problems in excel You can find it discussed at https social technet microsoft com Forums exchange en US 3f29c84b 97ad 46f7 9bc0 8648d69336ce kb2553154 breaks our excel macros forum officeitproprevious fix is to simply delete the file MSForms exd from any Temp subfolder in the user s profile For instance C Users user name AppData Local Temp Excel8 MSForms exd C Users user name AppData Local Temp VBE MSForms exd C Users user name AppData Local Temp Word8 MSForms exd You can search for any files ending in exd and delete them while excel is closed Then start excel again and it should work properly Microsoft are aware of this issue and are trying to fix it apparently More information is at http stackoverflow com questions 27411399 microsoft excel activex controls disabled 441IPOWER 4 5 6 Manual Appendix B License Agreement Ridley Engineering Inc Ridley Engineering Europe UK Ltd Software License and Limited Warranty Statement SOFTWARE LICENSE 1 License Grant Ridley Engineering Inc or Ridley Engineering Europe UK Ltd referred to as Ridley grants to the registered purchaser referred to as you and your a nonexclusive right to use one copy of th
37. t available 1 506 W 18 not available 70 not available ium Core Loss for Selected Material Inductance AL value Core Loss 0 10617 W cu cm Core Loss Total 0457 W Design Requires 955 55 Selected Material 4125 H 2 i m tics Test Setup 2 nH or Impedance Fig 4 4 Inductor Core Material Selection You can use any core selection with a variety of core materials POWER 4 5 6 incorporates a unique core loss modeling techniques that accurately give the loss for different materials Variable Steinmetz equation coefficients are used to produce a much more accurate core loss estimate than is available from the manufacturers Details of the techniques used to calculate the loss are given in the Ridley Engineering Design Center www http www ridleyengineering com design center html in paper A03 Modeling Ferrite Core Losses If you are using a different core material to those shown POWER 4 5 6 gives you the proper frequency flux level and Delta B to be used with core loss curves Z30IPOWER 4 5 6 Manual 4 5 Designing Inductor Windings M INDUCTOR DESIGN Inductor Value Number of Turns 12 is Core and Gap Sore Material gt AVAILABLE WINDOW mm each end Insulation Required q mm total Margin Required vy S Available Window Winding WINDING STRUCTURE C Use Magnet Wire Use Foil Maximum Conductor Size That Will F
38. ure 3 2 shows the transfer functions for current mode control the default control scheme chosen for all converters except the half bridge 23IPOWER 4 5 6 Manual OPERATING PARAMETERS Switching Frequency kHz 192 kHz Default Current Limit A 0 854 A Default CONTROLLER PARAMETERS Controller Type Custom Controller Select IC Duty Cycle Limit 0 6 Default Reference Voltage t V Default Ve Max E V Default Gain After Error Amplifier Default Controller Dissipation E W Defaul Current Mode Control PWM DUTY CYCLE RANGE Calculated Minimum Calculated Maximum Loop Test Setup Present Simulation ee He CONTROLLER L PWM Controller Fig 3 3 Voltage Mode Control Transfer Function Bode Plots in POWER 4 5 6 If you click on the controller shown just below the graphs above you can change your selection to voltage mode control Once you do this the compensator will be re optimized and the resulting transfer functions plotted You will notice that in voltage mode control the gain of the power stage and the loop gain are directly affected by the input voltage 24IPOWER 4 5 6 Manual 10000 100000 Compensation Zeros FirstZero 2163 Hz 8 Hz Default DW Compensation Poles Second Pole Hz Hz Default ajv RESET Loop Loop Test Setup Fig 3 4 Interactive Adjustment of Compensation Poles and Zeros with Transfer Functions It is possible to look at the control transfer functions of POWER
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