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Design Example Report
Title Specification Application Author Document Number Date Revision 2.4W Charger using LNK500P Input: 90-264 VAC Output: 6V / 0.4A Cell Phone Charger Power Integrations Applications Department DER-12 February 4, 2004 1.0
Summary and Features
This report details the design of an isolated Flyback converter for Wall mount adapter. * * * * * Uses LinkSwitch LNK500P (Low cost series) Universal input voltage Typical Efficiency 72 % Meets EN550022 Class B EMI tests with No Y1 capacitor Very low earth leakage current
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
Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Applications Hotline: Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com
DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
Table Of Contents
Introduction................................................................................................................. 4 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 PCB Layout ................................................................................................................ 5 Bill Of Materials .......................................................................................................... 6 Transformer................................................................................................................ 7 6.1 Transformer Winding........................................................................................... 7 6.2 Electrical Specifications....................................................................................... 7 6.3 Transformer Construction.................................................................................... 8 6.4 Winding Instructions ............................................................................................ 8 6.5 Materials.............................................................................................................. 9 6.6 Design Notes:...................................................................................................... 9 7 Performance Data .................................................................................................... 10 7.1 Efficiency........................................................................................................... 10 7.2 Load Regulation ................................................................................................ 11 7.3 Line Regulation ................................................................................................. 11 7.4 No Load Input Power......................................................................................... 12 7.5 Output Ripple Measurements............................................................................ 13 7.5.1 Ripple Measurement Technique ................................................................ 13 7.5.2 Output Voltage Ripple ................................................................................ 14 8 Surge Test................................................................................................................ 14 9 EMI Tests ................................................................................................................. 15 10 Revision History.................................................................................................... 17 1 2 3 4 5 6
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
List Of Figures
Figure 1 - Flyback Converter - 2.4W 6V 0.4A................................................................................................ 5 Figure 2 - PCB Layout .................................................................................................................................... 5 Figure 3 - Transformer Winding...................................................................................................................... 7 Figure 4 - Transformer construction ............................................................................................................... 8 Figure 5 - Efficiency Vs Output Current ........................................................................................................ 10 Figure 6 - Load Regulation ........................................................................................................................... 11 Figure 7 - Line Regulation ............................................................................................................................ 11 Figure 8 - No Load Input Power.................................................................................................................... 12 Figure 9 - Oscilloscope Probe Prepared for Ripple Measurement............................................................... 13 Figure 10 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter .................................................. 13 Figure 11 - Output Voltage Ripple (worst case) at Vin = 90 Vac, Vo = 5.44 V, Io = 400 mA ....................... 14 Figure 12 - EN55022 Class B, Line, artificial hand connected to output return ........................................... 15 Figure 13 - EN55022 Class B, Neutral, artificial hand connected to output return....................................... 15 Figure 14 - EN55022 Class B, Line, with out artificial hand connected to output return .............................. 16 Figure 15 - EN55022 Class B, Neutral, with out artificial hand connected to output return ......................... 16
List Of Tables
Table 1 - Power Supply Specification ______________________________________________________ 4 Table 2 - Bill of Materials ________________________________________________________________ 6 Table 3 - Transformer BOM______________________________________________________________ 9
Important Notes: 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. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
1 Introduction
This document is an engineering report giving performance characteristics of an isolated Flyback converter with universal input voltage and 6V 0.4A output CV/CC characteristics. This design uses LinkSwitch - an integrated IC comprising a high voltage MOSFET, PWM controller, using no optocoupler. The controller provides an I2f type characteristic to provide a constant current output current without secondary side sensing. This document contains the power supply specification, schematic, and bill of materials, transformer documentation, printed circuit layout, and performance data.
2 Power Supply Specification
Description Input Voltage Output Output Voltage @ full load Output Voltage @ no load Output Ripple Voltage Total Output Power Continuous Output Power Constant Current Limit Output Constant Current Conducted EMI Margin Efficiency Ambient Temperature TAMB -10 POUT 2.4 W Symbol VIN Vfl Vnl VRIPPLE1 Min 90 5.3 6.6 Typ Max 264 Units Vac V V mV
at 400 mA load 20 MHz Bandwidth
Comment
6.8 150
IOUT1
.4
.5
.65
A
2.5V - 4.5V
5 72 40
dB
o
EN550022 B, FCC B At full load Free convection, Sea level
% C
Table 1 - Power Supply Specification
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
3 Schematic
D3 1N4005 D1 1N4005 L RF1 8.2 Ohm 1W
FUSIBLE
+
U1 LNK500P L1 1mH R3 1.5M C2 4.7uF 400V
+
D
S T1 C
1 5
6V 400 mA C5
W1,14T #28,TIW
+
C3
FL W3,98T,#36
4 6
R4 1.5M R1 19.1K
0.22uF, 50V
W2,9T,#36x5
3
11DQ06 D6 R5 EE13 Lp=2450uH 20 C6
470 uF, 10V
R6 24
D7 6.2Vz
85-265 VAC N
C1 4.7uF 400V
C4 0.1uF, 100V
RTN
1000 pF, 100V
D5 1N4937 D2 1N4005 L2 D4 1N4005 Ferrite Bead R2 100
Figure 1 - Flyback Converter - 2.4W 6V 0.4A.
4 PCB Layout
Figure 2 - PCB Layout
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Page 5 of 19
DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
5 Bill Of Materials
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Qty 2 1 1 1 1 4 1 1 1 1 1 1 1 1 2 1 1 1 1 Ref. Des C1, C2 C3 C4 C5 C6 D1, D2, D3, D4 D5 D6 D7 L1 L2 RF1 R1 R2 R4, R3 R5 R6 T1 U1 Part Description 4.7 F, 400V, AL Electrolytic capacitor 0.22 F, 50V, Ceramic capacitor 0.1 F, 100V, Film capacitor 470 F, 10V, Low ESR AL Electrolytic capacitor 1000 pF, 100V, Ceramic capacitor 1N4005, Diode GP 1A 600V 1N4937, Diode FR 1A 600V 11DQ06, Diode Schottky 1A 60V 6.2Vz, Diode Zener, 500 mW, 1% 1 mH, Inductor drum core Ferrite Bead 8.2 1W, Resistor fusible 19.1 K, Resistor 1/4 W, 1% 100 , Resistor, 1/8 W, 5% 1.5 M, Resistor 1/8 W, 5% 20 , Resistor, 1/8 W, 5% 24 , Resistor, 1/8 W, 5% Flyback Transformer LNK500P, LinkSwitch Table 2 - Bill of Materials
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
6 Transformer
6.1 Transformer Winding
1 W3,Primary, 96T,#36 4 4 W2,Shield Wndg, 9T,#35x5 3 5 W1,Secondary, 13T,#28 TIW 6
Figure 3 - Transformer Winding
6.2
Electrical Specifications
60Hz 1minute, from Pins 1-4 to Pins 5-6 All windings open All windings open L13 with pins 5-6 shorted 3 kV for 1 minute 2.45 mH 7 % 300 kHz min. 50 H max.
Electrical Strength Primary Inductance (Pin 1 to Pin 3) Resonant Frequency Primary Leakage Inductance
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
6.3
Transformer Construction
Pins 5-8 Pins 1-4 0.29",2mils Insulation Tape, 1 layer 1 place, 2 layer 3 places, 3 layer 1 place W3-finish W3-start W2-finish W2-start W1-start W1-finish
Flux Band
Figure 4 - Transformer construction
6.4
Winding Instructions
Place the bobbin on the winding machine with pins 1-4 on the right side and pins 5-8 on the left side. W1 (Secondary Winding) Basic Insulation W2 (Shield) Wind 13 turns with # 28 triple insulated wire from right to left starting temporarily from 1 and finishing at 5. Bring the starting end from pin 1 to pin 6. 2 layers of tape for insulation. Wind 9 turns with #35 x 5 (penta-filar) magnet wire from right to left starting from 4 and finishing at 3. Wind evenly across the width of the bobbin without any gaps on sides. 2 layers of tape for insulation. Wind 96 turns in 2 layers with # 36 AWG magnet wire - first layer 48T from right to left starting from pin 1 - one layer of insulation tape - second layer 48T from left to right and finishing at pin 4. 3 layers of tape for insulation. Assemble and secure core halves. Apply Flux band around assembled core and bobbin, and solder start and finish ends. Connect the flux band to pin 3 with a piece of #35 AWG magnet wire. 2 layers of tape for insulation. Solder the transformer pins and impregnate transformer uniformly with varnish.
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Basic Insulation W3 (Primary Winding)
Basic Insulation Core Assembly Flux Band
Outer Insulation Final Assembly
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DER-12 6.5 Materials Item [1] [2] [3] [4] [5] [6] [7] [8]
2.4W Cell Phone Charger using LNK500P
February 4, 2004
Description Core: EE13, PC40EE13, TDK Gapped for AL = 222 nH/T2 7 % Bobbin: Horizontal 8 pins Magnet Wire: #36 AWG Magnet Wire: #35AWG Triple Insulated wire: # 28 AWG Copper foil, 0.2 inch x 2 mils Tape: 3M 1298 Polyester Film (white) 0.29" x 2 mils Varnish
Table 3 - Transformer BOM
6.6
Design Notes: LNK500P 42 KHz discontinuous 0.25 A 54 V 264 V 90 V
Power Integrations Device Frequency of Operation Mode Peak Current Reflected Voltage (Secondary to Primary) Maximum AC Input Voltage Minimum AC Input Voltage
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
7 Performance Data
Measurements shown are of a typical unit. The output voltages are measured at the end of a 6-foot cable with 0.2 total resistance. 7.1 Efficiency
The measurements are made for various load and line conditions. The efficiencies are calculated and shown in Figure 5.
Efficiency Vs Output Current
80.00 75.00 70.00 65.00 60.00 55.00 50.00 45.00 40.00 35.00 30.00 50 100 150 200 250 300 Output Current (mA)
Efficiency (%)
Vin = 90 Vac Vin = 120 Vac Vin = 230 Vac Vin = 264 Vac 350 400
Figure 5 - Efficiency Vs Output Current
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DER-12 7.2
2.4W Cell Phone Charger using LNK500P
February 4, 2004
Load Regulation
Load Regulation
7 6 Output Voltage (V) 5 4 3 2 1 0 0 100 200 300 400 500 600 Output Current (mA) Vin = 90 Vac Vin = 120 Vac Vin = 230 Vac Vin = 264 Vac
Figure 6 - Load Regulation
7.3
Line Regulation
Line Regulation 6.5 6.25 Output Voltage (V) 6 5.75 5.5 5.25 5 4.75 4.5 90 120 150 180 210 240 270 Input Voltage (Vac) Io = 100 mA Io = 200 mA Io = 300 mA Io = 400 mA
Figure 7 - Line Regulation
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
7.4
No Load Input Power
No Load Input Power
500 450 400 350 300 250 50 100 150 200 250 300 Input Voltage (Vac)
Io = 0 mA
Input Power (mW)
Figure 8 - No Load Input Power
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DER-12 7.5
2.4W Cell Phone Charger using LNK500P
February 4, 2004
Output Ripple Measurements
7.5.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 9 and Figure 10. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 9 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 10 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added).
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
7.5.2 Output Voltage Ripple
Figure 11 - Output Voltage Ripple (worst case) at Vin = 90 Vac, Vo = 5.44 V, Io = 400 mA
8 Surge Test
Surge test was done as per IEC1000-4-5, but with 2.5kV line-line, 2 impedance, with 8 strikes each at +2.5kV at 90 and -2.5kV at 270. The unit passed without any failure.
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
9 EMI Tests
The EMI tests are done at 220 Vac input and 400 mA load.
Figure 12 - EN55022 Class B, Line, artificial hand connected to output return
Figure 13 - EN55022 Class B, Neutral, artificial hand connected to output return
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
Figure 14 - EN55022 Class B, Line, without artificial hand connected to output return
Figure 15 - EN55022 Class B, Neutral, without artificial hand connected to output return
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
10 Revision History
Date February 4, 2004 Author YG Revision 1.0 Description & changes Initial release Reviewed AM/VC
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DER-12
2.4W Cell Phone Charger using LNK500P Notes
February 4, 2004
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DER-12
2.4W Cell Phone Charger using LNK500P
February 4, 2004
For the latest updates, visit our Web site: 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, nor does it convey any license under its patent rights or the rights of others. 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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations, Inc. PI Expert and DPA-Switch are trademarks of Power Integrations, Inc. (c) Copyright 2003, Power Integrations, Inc.
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