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Title
Engineering Prototype Report for EP-73 2.3 W CV/CC Charger/Adapter Using LinkSwitch(R)-HF (LNK354P)
Specification 85-265 VAC Input, 5.7 V, 400 mA Output Application Author Document Number Date Revision
Low Cost Charger or Adapter
Power Integrations Applications Department EPR-73
25-Oct-04
1.0
Summary and Features * * * * * * Low cost, low component count battery charger or adapter solution No-load power consumption <300 mW at 265 VAC input meets worldwide energy conservation guidelines Output voltage (CV) tolerance: 10% across operating range Output current (CC) tolerance: 12% across operating range Meets EN550022 and CISPR-22 Class B EMI with low value Y1 safety capacitor Ultra-low leakage current: <10 A at 265 VAC input
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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
Table Of Contents
Introduction.................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic...................................................................................................................6 Circuit Description ......................................................................................................7 4.1 Input EMI Filtering ...............................................................................................7 4.2 LinkSwitch-HF Primary ........................................................................................7 4.3 Output Rectification .............................................................................................7 4.4 Output Feedback.................................................................................................7 4.5 Design Aspects for EMI .......................................................................................8 5 PCB Layout ................................................................................................................9 6 Bill Of Materials ........................................................................................................10 7 Transformer Specification.........................................................................................11 7.1 Electrical Diagram .............................................................................................11 7.2 Electrical Specifications.....................................................................................11 7.3 Materials............................................................................................................11 7.4 Transformer Build Diagram ...............................................................................12 7.5 Transformer Construction..................................................................................12 8 Transformer Design Spreadsheet.............................................................................13 9 Performance Data ....................................................................................................16 9.1 Efficiency ...........................................................................................................16 9.2 No-load Input Power..........................................................................................17 9.3 Regulation .........................................................................................................17 9.3.1 CV and CC Output Characteristics.............................................................17 9.3.2 Load Regulation in CV ...............................................................................18 10 Thermal Performance ...........................................................................................19 11 Line Surge.............................................................................................................20 12 Waveforms............................................................................................................21 12.1 Drain Voltage and Current, Normal Operation...................................................21 12.2 Output Voltage Start-up Profile..........................................................................22 12.3 Drain Voltage and Current Start-up Profile ........................................................22 12.4 Load Transient Response (75% to 100% Load Step) .......................................23 12.5 Output Ripple Measurements............................................................................24 12.5.1 Ripple Measurement Technique ................................................................24 12.5.2 Measurement Results ................................................................................25 13 Conducted EMI .....................................................................................................26 13.1 115 VAC Input, Full Load ..................................................................................26 13.2 230 VAC Input, Full Load ..................................................................................27 14 Appendix A............................................................................................................28 15 Revision History ....................................................................................................33 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.
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1 2 3 4
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EP-73 5.7 V, 400 mA Charger / Adapter
1 Introduction
This document is an engineering report describing a 5.7 V, 400 mA power supply utilizing a LNK354P device. This power supply is intended as a general purpose evaluation platform for LinkSwitch-HF devices in a battery charger application with secondary side CV/CC control. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
Figure 1 - EP73 Populated Circuit Board Photograph.
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Efficiency Environmental Conducted EMI Safety Surge Surge Ambient Temperature
* Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II > 6 dB Margin
Symbol VIN fLINE
Min 85 47
Typ
Max 265 64 0.3 6.3 100 450 2.8*
Units VAC Hz W V mV mA W %
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1
5.2 350 1.82 55
5.7 400 2.3
5% 20 MHz bandwidth With battery model attached to end of output cable, measured at 25 C
POUT
Measured at POUT (1.8 W), o 230 VAC, 25 C
2 2 TAMB 0 50
kV kV
o
1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: 12 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level
C
Maximum output power of the LNK354 is restricted by enclosure size - higher powers are possible with larger enclosures and PCB heatsink area.
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Page 4 of 36
25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
7
6
5
Output Voltage (V)
4
3
2
1
0 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Output Current (A)
Figure 2 - Output CV/CC Envelope Specification.
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
3 Schematic
Figure 3 - EP73 Schematic.
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
4 Circuit Description
This circuit is configured as a flyback topology power supply utilizing the LNK354P. Secondary side constant voltage (CV) and constant current (CC) feedback circuitry provides characteristics required for battery charging applications. 4.1 Input EMI Filtering The AC input voltage is rectified by input bridge D1 - D4. The rectified DC is then filtered by the bulk storage capacitors C1 and C2. Inductor L1, C1 and C2 form an input pi filter, which attenuates differential mode conducted EMI. It is recommended that RF1 be of wire-wound construction to withstand input current surges while the input capacitor charges (metal film type are not recommended), and be compliant with safety flammability hazard requirements. Please consult your safety agency representative for requirements specific to your application. 4.2 LinkSwitch-HF Primary The LNK354P device U1 integrates the power switching device, oscillator, control, startup, and protection functions. The integrated 700 V MOSFET has excellent switching characteristics allowing operation at the 200 kHz operating frequency. The rectified and filtered input voltage is applied to the primary winding of T1. The other side of the transformer primary is driven by the integrated MOSFET in U1. Diode D5, C3, R1, R2, and R3 form the primary clamp network. This limits the peak drain voltage due to leakage inductance. Resistor R3 allows the use of a slow, low cost rectifier diode by limiting the reverse current through D5 when U1 turns on. The selection of a slow diode also improves conducted EMI. To regulate the output, ON/OFF control is used. During normal operation, switching of the power MOSFET is disabled when a current greater than 49 A is delivered into the FEEDBACK pin. Current lower than this threshold allows a switching cycle to occur terminating when the peak primary current reaches the internal current limit. Current into the FEEDBACK pin is fed, via optocoupler U2, from the BYPASS pin removing the need for an auxiliary bias winding on the transformer. 4.3 Output Rectification Output rectification is provided by Schottky diode D6. The low forward voltage provides high efficiency across the operating range. Low ESR capacitor C6 achieves minimum output voltage ripple and noise in a small can size for the rated ripple current specification. 4.4 Output Feedback Output voltage, in constant voltage (CV) mode, is set by the Zener diode VR1 plus emitter-base voltage of PNP transistor Q1. The VBE of Q1 divided by the value of R7 sets
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
the bias current through VR1 (~2.7 mA). When the output voltage exceeds the threshold voltage determined by Q1 and VR1, Q1 is turned on and current flows through the LED of U2. As the LED current increases, the current fed into the FEEDBACK pin increases disabling further switching cycles of U1. At very light loads almost all switching cycles will be disabled, giving a low effective switching frequency and providing low no-load consumption. Resistors R6 and R8 ensure that the ratings of Q1 are not exceeded during load transients. Resistors R9 and R10 form the constant current (CC) sense circuit. Above approximately 400 mA, the voltage across the sense resistor exceeds the optocoupler diode forward conduction voltage of approximately 1 V. The current through the LED is therefore determined by the output current and CC control dominates the CV feedback loop. 4.5 Design Aspects for EMI In addition to the simple input pi filter for differential mode EMI, this design makes use of shielding techniques in the transformer to reduce common mode EMI displacement currents. Resistor R5 and C5 are added to act as a damping network to reduce high frequency transformer ringing. To return high frequency common mode displacement currents, a small value (100 pF) Y1 safety capacitor is placed across the isolation barrier. This is a small enough value to still meet the design requirement of low leakage current. These techniques combined with the frequency jitter of LinkSwitch-HF give excellent conducted and radiated EMI performance.
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Page 8 of 36
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EP-73 5.7 V, 400 mA Charger / Adapter
5 PCB Layout
Figure 4 - Printed Circuit Layout (Approximately 1.2 x 1.8 inches).
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
6 Bill Of Materials
Item Qnty Ref. Des. Value 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 2 1 1 1 1 1 4 1 1 2 1 3 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 C1, C2 C3 C4 C5 C6 CY1 D1, D2, D3, D4 D5 D6 J1,J2 J3 4.7 F 2.2nF 100 nF 2.2 nF 330 F 100 pF 1N4005 DL4007 Description 4.7 F, 400 V, Electrolytic, (8 x 11.5) 4.7 F, 380 V, Electrolytic, (8 x 11.5) 2.2 nF, 400 V, Film 100 nF, 50 V, Ceramic, X7R, 0805 2.2 nF, 50 V, Ceramic, X7R, 0805 330 F, 16 V, Electrolytic, Very Low ESR, 72 m, (8 x 11.5) 100 pF, Ceramic, Y1 600 V, 1 A, Rectifier, DO-41 1000 V, 1 A, Rectifier, Glass Passivated, DO-213AA (MELF) 40 V, 1 A, Schottky, DO-214AC Mfg Part Number Manufacturer SHD400WV 4.7uF Sam Young XX380VB4R7M8X11LL United Chemi-Con 222237065222 ECU-V1H221KBN ECJ-2VB1H222K KZE16VB331MH11LL 440LT10 1N4005 DL4007 SS14 N/A 3PH243 298 SBCP-47HY102B MMST3906-7 ERJ-6GEYJ473V ERJ-6GEYJ201V ERJ-6GEYJ512V ERJ-6GEYJ680V ERJ-6GEYJ6R8V ERJ-6GEYJ221V ERJ-6GEYJ391V RSF100JB-2R4 Vishay (BC Components) Panasonic Panasonic Nippon Chemi-Con Vishay Vishay Diodes Inc Vishay N/A Anam Instruments (Korea) Alpha Tokin Diodes Inc Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Yageo Vitrohm Hical Li Shin Vogt Power Integrations Sharp, ISP Vishay
SS14 PCB Terminal 22 PCB Terminal Hole, 22 AWG AWG Output Cable 6 ft, 0.25 , 2.1 mm connector (custom) Assembly
JP1, JP2, J JP3 L1 1 mH Q1 R1, R2 R3, R9 R4 R5 R6 R7 R8 R10 RF1 T1 U1 U2 VR1 MMST3906 47 k 200 5.1 k 68 6.8 220 390 2.4 8.2 EE16 LNK354P PC817D BZX79-B5V1
Wire Jumper, Non insulated, 22 AWG, 0.4 in 1 mH, 0.15 A, Ferrite Core PNP, Small Signal BJT, 40 V, 0.2 A, SOT-323 47 k, 5%, 1/8 W, Metal Film, 0805 200 , 5%, 1/8 W, Metal Film, 0805 5.1 k, 5%, 1/8 W, Metal Film, 0805 68 , 5%, 1/8 W, Metal Film, 0805 6.8 , 5%, 1/8 W, Metal Film, 0805 220 , 5%, 1/8 W, Metal Film, 0805 390 , 5%, 1/8 W, Metal Film, 0805 2.4 , 5%, 1 W, Metal Oxide
8.2 , 2.5 W, Fusible/Flame-Proof Wire-Wound CRF253-4 5T 8R2 Sil6032 Custom LSLA40331B IM 040 416 11 LinkSwitch-HF, LNK354P, DIP-8B LNK354P Optocoupler, 80 V, CTR 300-600%, 4-DIP 5.1 V, 500 mW, 2%, DO-35 PC817X4, IPC817D BZX79-B5V1
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Page 10 of 36
25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
7 Transformer Specification
7.1 Electrical Diagram
5
Winding #1
28 T 2 x 37 AWG
N/C N/C 9
Floating
Winding #3
6T 4 x 28 AWG
4 3
9T 25 AWG Winding #4 T.I.W.
8
Winding #2
114 T 34 AWG
5
Figure 5 - Transformer Electrical Diagram.
7.2
Electrical Specifications
60 Hz 1 minute, from Pins 3-5 to Pins 6-10 Pins 3-5, all other windings open, measured at 200 kHz, 0.4 VRMS Pins 3-5, all other windings open Pins 3-5, with Pins 8-9 shorted, measured at 200 kHz, 0.4 VRMS 3000 VAC 916 H, -/+12% 900 kHz (Min.) 75 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] Description Core: PC40EE16-Z, TDK or equivalent Gapped for AL of 70 nH/T2 Bobbin: EE16 Horizontal 10 pin Magnet Wire: #37 AWG Magnet Wire: #34 AWG Magnet Wire: #28 AWG Triple Insulated Wire: #25 AWG. Tape: 3M 1298 Polyester Film, 2.0 mils thick, 8.4 mm wide Varnish
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
7.4
Transformer Build Diagram
8
9 4 5
Floating
Secondary Winding
Shield
Primary Winding
3
4 layers of tape
5
Floating
Cancellation Winding
Figure 6 - Transformer Build Diagram.
7.5
Transformer Construction
Primary pin side of the bobbin oriented to left-hand side. Start at Pin 8 temporarily. Wind 28 bifilar turns of item [3] from right to left. Wind with tight tension across entire bobbin evenly and leave the finish end free. Bend the free end 90 and draw the wire across the bobbin window cutting in the center of the bobbin. Move start end of winding from Pin 8 to Pin 5. 4 Layers of tape [6] for insulation. Start at Pin 3 wind 38 turns of item [4] from left to right. Add one layer of tape. Wind another 38 turns from right to left. Add one layer of tape. Wind 38 turns in third layer from left to right. Wind with tight tension across entire bobbin evenly. Finish at Pin 5. 2 Layers of tape [6] for insulation. Start at Pin 8 temporarily, wind 6 quadfilar turns of item [5]. Wind from right to left with tight tension in a single uniform layer across entire width of bobbin. Finish on Pin 4. Cut start end at Pin 8 ensuring uniformity of winding and tape down in place. 2 Layers of tape [7] for insulation. Start at Pin 9, wind 9 turns of item [6] from right to left. Wind uniformly, in a single layer across entire bobbin width. Finish on Pin 8. 3 Layers of tape [7] for insulation. Assemble and secure core halves. Dip Varnish [8] - DO NOT VACUUM IMPREGNATE
First Winding Cancellation
Insulation Second Winding Primary Insulation Third Winding Shield Insulation Fourth Winding Outer insulation Core Assembly Varnish
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
8 Transformer Design Spreadsheet
ACDC_LinkSwitchHF_060904; Rev1-1; INPUT INFO Copyright Power Integrations Inc. 2004 ENTER APPLICATION VARIABLES VACMIN 85 VACMAX 265 fL 50 VO 5.7 IO 0.4 CC Threshold Voltage PO n Z tC CIN 0.57 0.75 3 9.4 1.04 2.696 OUTPUT UNIT ACDC_LinkSwitch-HF_060904_Rev1-1.xls; LinkSwitchTN_HF Continuous/Discontinuous Flyback Transformer Design Spreadsheet
Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Power Supply Output Current Voltage drop across sense resistor. For CV only circuits enter Volts "0" Watts Output Power Efficiency Estimate. For CV only designs enter 0.7 if no better data available Loss Allocation Factor mSeconds Bridge Rectifier Conduction Time Estimate uFarads Input Capacitance
Volts Volts Hertz Volts Amps
ENTER LinkSwitch-HF VARIABLES LinkSwitch-HF LNK354 Chosen Device ILIMITMIN ILIMITMAX fS fS Full Load VOR VDS VD KP 178750 91 0.45 LNK354 Power Out 0.233 0.268 186000 178750 91 10 0.45 1.15
Universal 4.5 W Amps Amps Hertz Hertz Volts Volts Volts
115 Doubled/230V 5W Minimum Current Limit Maximum Current Limit Minimum Device Switching Frequency Maximum switching frequency at full load and LP min. For maximum power capability enter 186 kHz (fs_min), reducing this value will reduce EMI but lower power capability Reflected Output Voltage LinkSwitch-HF on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.6ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE16 EE16 Core EE16 P/N: Bobbin EE16_BOBBIN P/N: AE 0.192 cm^2 LE 3.5 cm AL 1140 nH/T^2 BW 8.6 mm M L NS 9 0 3 9 90 375 Volts Volts mm
DC INPUT VOLTAGE PARAMETERS VMIN VMAX
CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.54 IAVG 0.05 IP 0.23 IR 0.23 IRMS 0.09
Amps Amps Amps Amps
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
TRANSFORMER PRIMARY DESIGN PARAMETERS LP 916 LP_TOLERANCE 12 NP 114 ALG 71 BM BAC ur LG BWE OD INS DIA AWG CM CMA Caution 1298 649 1654 0.32 25.8 0.23 0.05 0.18 34 40 466
uHenries % nH/T^2 Gauss Gauss mm mm mm mm mm AWG Cmils Cmils/Amp
Typical Primary Inductance. +/- 12% Primary inductance tolerance Primary Winding Number of Turns Gapped Core Effective Inductance !!! Caution. Flux densities above ~ 1250 Gauss may produce audible noise. Verify with dip varnished sample transformers. Increase NS to greater than or equal to 10 turns or increase VOR AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < 500)
TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP 2.95 ISRMS 1.02 IRIPPLE 0.94 CMS 205 AWGS 26 DIAS 0.41 ODS 0.96 INSS 0.27 VOLTAGE STRESS PARAMETERS VDRAIN PIVS 586 35
Amps Amps Amps Cmils AWG mm mm mm Volts Volts
Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 5.7 Volts Output Voltage (if unused, defaults to single output design) IO1 0.473 Amps Output DC Current PO1 2.70 Watts Output Power VD1 0.45 Volts Output Diode Forward Voltage Drop NS1 8.34 Output Winding Number of Turns ISRMS1 1.210 Amps Output Winding RMS Current IRIPPLE1 1.11 Amps Output Capacitor RMS Ripple Current PIVS1 33 Volts Output Rectifier Maximum Peak Inverse Voltage CMS1 AWGS1 DIAS1 ODS1 2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 CMS2 AWGS2 DIAS2 ODS2 242 26 0.41 1.03 Cmils AWG mm mm Volts Amps Watts Volts Amps Amps Volts Cmils AWG mm mm Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
0.00 0.00 0.000 0.00 0 0 N/A N/A N/A
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Page 14 of 36
25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 CMS3 AWGS3 DIAS3 ODS3 Total power
0.00 0.00 0.000 0.00 0 0 N/A N/A N/A 2.696
Volts Amps Watts Volts Amps Amps Volts Cmils AWG mm mm Watts
Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Total Output Power
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. A DC output cable was not included. 9.1 Efficiency
65%
60%
Efficiency
55%
90 VAC
50%
115 VAC
230 VAC
265 VAC
45%
40% 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
Output Load (A)
Figure 7 - Efficiency vs. Output Current (CV), Room Temperature, 60 Hz.
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25-Oct-2004 9.2 No-load Input Power
0.3
EP-73 5.7 V, 400 mA Charger / Adapter
0.25
Input Power (W)
0.2
0.15
0.1
0.05
0 50 100 150 200 250 300
Input Voltage (VAC)
Figure 8 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
9.3
Regulation
9.3.1 CV and CC Output Characteristics No measurable difference was seen over line voltage variation.
7
6
5
Output Voltage (V)
4
3
2
1
0 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Output Current (A)
Figure 9 - CV/CC Output Characteristic with Specification Limits Added, Room Temperature.
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EP-73 5.7 V, 400 mA Charger / Adapter 9.3.2 Load Regulation in CV
7
25-Oct-2004
6.5
Output Voltage (V)
6
5.5
5
4.5
4 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Output Load (A)
Figure 10 - Load Regulation in CV Operation, Room Temperature, Full Load.
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
10 Thermal Performance
Temperature of key components was recorded using a T-type thermocouple. Thermocouples were soldered directly to LNK354P SOURCE pin and cathode of output rectifier. Thermocouples were glued to the output capacitor and transformer external core/winding surfaces. The unit was operated at full load in free convection in a thermal chamber inside an additional enclosure to eliminate airflow. The ambient was measured in the additional enclosure and maintained at 40 C.
Temperature (C) Item Ambient LNK354P (U1) Transformer (T1) Output Rectifier (D6) Output Capacitor (C6) 85 VAC 40 94 80 67 60 265 VAC 40 96 82 64 58
For reference an infrared thermograph was taken with the unit operating at room ambient showing the relative temperature rise of the key supply components.
Figure 11 - Infrared Thermograph of PCB (85 VAC, Room Ambient).
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
11 Line Surge
Surge Voltage 2 kV 2 kV Phase Angle 90 90 Generator Impedance 2 12 Number of Strikes 10 10 Test Result PASS PASS
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Page 20 of 36
25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
12 Waveforms
12.1 Drain Voltage and Current, Normal Operation
Figure 12 - 115 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 50 V, 200 ns / div.
Figure 13 - 230 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V, 100 ns / div.
Figure 14 - 115 VAC, Full Load. VDRAIN, 50 V, 20 s / div.
Figure 15 - 115 VAC, Full Load. VDRAIN, 100 V, 20 s / div.
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
12.2 Output Voltage Start-up Profile Startup into resistive full load and no-load was verified. Load resistor was sized at 13 to maintain 300 mA under steady-state conditions.
Figure 16 - Start-up Profile115 VAC. Fast trace is no load rise time. Slower trace is maximum load (13 ) 1 V, 2 ms / div.
Figure 17 - Start-up Profile 230 VAC. Fast trace is no load rise time. Slower trace is maximum load (13 ) 1 V, 2 ms / div.
12.3 Drain Voltage and Current Start-up Profile
Figure 18 - 90 VAC Input and Maximum Load (Resistive Load). Upper: 200 V & 500 s/ div. Lower: VDRAIN, IDRAIN, 0.1 A / div.
Figure 19 - 265 VAC Input and Maximum Load (Resistive Load). Upper: 200 V & 500 s/ div. Lower: VDRAIN, IDRAIN, 0.1 A / div.
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
12.4 Load Transient Response (75% to 100% Load Step)
Figure 20 - Transient Response, 115 VAC, 75-100-75% Load Step. Upper:. VOUT 20 mV, 1 ms / div. Lower: IOUT, 0.1 A / div.
Figure 21 - Transient Response, 230 VAC, 75-100-75% Load Step. Upper: VOUT, 20 mV, 1ms / div. Lower: IOUT, 0.1 A / div.
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
12.5 Output Ripple Measurements 12.5.1 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. Attach probe with end cap and ground clip removed to circuit shown below which is attached to end of output cable. The 5125BA probe adapter is affixed
Probe Ground
Probe Tip
Figure 22 - Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).
RCABLE (0.15 ) DA RBATTERY (0.44 ) DB CA RLOAD (13 ) 10,000 F
Figure 23 - Equivalent Battery Model Circuit.
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
12.5.2 Measurement Results
Figure 24 - Output Ripple, 115 VAC, Full Load. 20 s, 50 mV / div.
Figure 25 - Output Ripple, 230 VAC, Full Load. 20 s, 50 mV / div.
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
13 Conducted EMI
Conducted emissions tests were completed at 115 VAC and 230 VAC at full load, 5.5 V / 400 mA. Measurements were completed with Artificial Hand connection and floating DC output load resistor. An output DC cable was included. Composite EN55022B / CISPR22B conducted limits are shown. 13.1 115 VAC Input, Full Load
Line Neutral
Artificial Hand Connected to Output Return
Artificial Hand Connected to Output Return
Output Floating
Output Floating
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
13.2 230 VAC Input, Full Load
Line Neutral
Artificial Hand Connected to Output Return
Artificial Hand Connected to Output Return
Output Floating
Output Floating
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
14 Appendix A - Design Modification Required To Remove Y Capacitor
In some applications where extremely low leakage current is required, it may be necessary to remove the Y capacitor (CY1) that bridges the primary-to-secondary isolation barrier. In order to achieve this while still meeting conducted and radiated EMI requires reoptimization of the transformer. As with all no Y capacitor transformer designs, the mechanical arrangement and relative spacing of the windings has a large impact on the EMI performance of the supply. Therefore ensure that transformers are wound consistently to ensure repeatable EMI performance. 14.1 No Y capacitor Transformer Specification 14.1.1 Electrical Diagram
5
Winding #1 (Cancellation)
Floating
17 T 2 x 32 AWG
N/C N/C 9
Winding #3 (Shield)
7T 3 x 28 AWG
4 3
9T Winding #4 25 AWG (Secondary) T.I.W.
8
Winding #2 (Primary)
114 T 36 AWG
5
Denotes mechanical start of reverse wound winding where electrical phasing and mechanical start are not the same
14.1.2 Electrical Specifications
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 60Hz 1minute, from Pins 3-5 to Pins 6-10 Pins 3-5, all other windings open, measured at 200 kHz, 0.4 VRMS Pins 3-5, all other windings open Pins 3-5, with Pins 8-9 shorted, measured at 200 kHz, 0.4 VRMS 3000 VAC 916 H, -/+12% 900 kHz (Min.) 75 H (Max.)
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
14.1.3 Winding Instructions
WD1 Cancellation Winding Insulation WD#2 Primary winding Primary pin side of the bobbin oriented to left-hand side. Add 1 layer of item [7] to the secondary side. Start at Pin 5. Wind 17 bifilar turns of item [3] from right to left. Wind with tight tension across entire bobbin evenly. Cut the ends of the bifilar and leave floating. 4 Layers of tape [8] for insulation. Apply 1 layer of item [7] to the secondary side. Start at Pin 3. Wind 40 turns of item [4] from left to right. Add 1 layer of item [8] and 1 layer of item [7] to the secondary side. Wind another 40 turns from right to left. Add 1 layer of item [8] and 1 layer of item [7] to the secondary side. Wind 34 turns in third layer from left to right. Wind with tight tension across entire bobbin evenly. Finish at Pin 5. 2 Layers of tape [8] for insulation. Start at Pin 8 temporarily, wind 7 trifilar turns of item [5]. Wind from right to left with tight tension. Wind uniformly, in a single layer across entire width of bobbin. Finish on Pin 4. Cut the lead of the starting end and ensure that the void area around the starting end is entirely covered with the cut end. Tape down in place. 2 Layers of tape [8] for insulation. Reverse orientation of bobbin such that secondary pin side is to the lefthand side. Start at Pin 8, wind 9 turns of item [6] from right to left. Wind uniformly, in a single layer across entire bobbin evenly. Finish on Pin 9. 3 Layers of tape [8] for insulation. Assemble and secure core halves using item [9]. Solder 1 end of item [10] to Pin 5. Wrap 2 turns around entire transformer making sure that wire is in contact with cores. Terminate end to Pin 5. Dip Varnish, item [11]
Insulation WD #3 Shield Winding
Insulation WD #4 Secondary Winding Outer Insulation Core Assembly Core Grounding Varnish
14.1.4 Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] Description Core: PC40EE16-Z, TDK or equivalent Gapped for AL of 192 nH/T2 Bobbin: EE16 Horizontal 10 pin Magnet Wire: #32 AWG Magnet Wire: #36 AWG Magnet Wire: #28 AWG Triple Insulated Wire: #25 AWG. Tape: 3M # 44 Polyester web. 1.5 mm wide Tape: 3M 1298 Polyester Film, 2.0 mils thick, 8.0 mm wide Tape: 3M 1298 Polyester Film, 2.0 mils thick, 3.0 mm wide Solid Wire: #28 AWG Varnish
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
14.1.5 Transformer Build Diagram
Secondary Shield 4 5
3 layers of tape 8 9
N.C. (Floating)
Primary 3
1.5 mm
Cancellation
5
1.5 mm
4 layers of tape Tape margin
N.C.
Denotes mechanical start of winding where mechanical start and electrical phase are different Denotes mechanical start and electrical phase of winding where they are the same
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25-Oct-2004
EP-73 5.7 V, 400 mA Charger / Adapter
14.2 EMI Results Both conducted and radiated EMI results with the revised transformer and CY1 removed showed excellent margin to respective standards. Tests were performed on both line and neutral (conducted) with the output return connected to the artificial hand input of the LISN (line impedance stabilization network). The red trace represents EMI measured with a quasi peak detector and the blue an average detector. These results should be below the respective limit line of the same color. Radiated results gave a margin of > 6dB.
Figure 26 - No Y Capacitor Conducted EMI Results (115 VAC).
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EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
Figure 27 - No Y Capacitor Conducted EMI (230 VAC).
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EP-73 5.7 V, 400 mA Charger / Adapter
15 Revision History
Date 01-Mar-04 01-Apr-04 05-Apr-04 08-Apr-04 28-Apr-04 02-May-04 Author AO PV PV AO PV Revision 0.1 0.2 0.3 0.4 0.5 0.6 Description & changes First Draft Transformer and layout change Applied correct template, updated circuit description Reinserted Figure 4 (didn't printout) Updated BOM, Spreadsheet, Schematic and Transformer 4.3: Change R2 to R3, replace terminated with disabled 4.4: Added 1 V opto threshold 6: Corrected description of D6 Fig 4: Added filar to diagram Added output characteristic spec Updated PCB layout, charts corrected R10 part number corrected Figure 2 updated (Q1 shown as NPN not PNP) Reinserted final spreadsheet Appendix A added for no Y cap solution
20-May-04 AO 27-May-04 PV 16-June-04 PV 24-June-04 PV 25-Oct-04 PV
0.7 0.8 0.81 0.9 1.0
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EP-73 5.7 V, 400 mA Charger / Adapter Notes
25-Oct-2004
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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25-Oct-2004 Notes
EP-73 5.7 V, 400 mA Charger / Adapter
Page 35 of 36
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EP-73 5.7 V, 400 mA Charger / Adapter
25-Oct-2004
For the latest updates, visit our website: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES 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. PATENT INFORMATION 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, DPA-Switch and EcoSmart are registered trademarks of Power Integrations. PI Expert and PI FACTS are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
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