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Design Example Report
Title Specification Application Author Document Number Date Revision 4.8W Charger using LNK520P Input: 85 - 265 VAC 50/60Hz Output: 12V / 400mA UPS Battery Charger Power Integrations Applications Department DER-56 April 20, 2005 1.0
Summary and Features * * * * * Low component count battery charger to replace linear transformer and regulator Highly efficient operation Current limited output Optimized switching characteristics minimizes EMI - Achieves greater than 8dBV margin to composite conducted limits - No Y1 safety capacitor required for EMI compliance Small low cost EE16 transformer
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
DER-56
UPS Battery Charger - LNK520
April 20, 2005
Table Of Contents
Introduction................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 Circuit Description ...................................................................................................... 6 4.1 Input EMI Filtering ............................................................................................... 6 4.2 LinkSwitch Primary and Output Feedback .......................................................... 6 4.3 Output Rectification ............................................................................................. 7 4.4 Output Feedback................................................................................................. 7 5 PCB Layout ................................................................................................................ 8 6 Bill Of Materials .......................................................................................................... 9 7 Transformer Specification......................................................................................... 10 7.1 Electrical Diagram ............................................................................................. 10 7.2 Electrical Specifications..................................................................................... 10 7.3 Materials............................................................................................................ 10 7.4 Transformer Build Diagram ............................................................................... 11 7.5 Transformer Construction.................................................................................. 11 8 Transformer Spreadsheet......................................................................................... 12 9 Performance Data .................................................................................................... 14 9.1 Efficiency at Full Load (400mA) ........................................................................ 14 9.2 Efficiency vs. Output Current............................................................................. 15 9.3 Efficiency and Input Power Comparison to Transformer + LDO........................ 16 9.4 No-load Input Power.......................................................................................... 17 9.5 Regulation ......................................................................................................... 18 9.5.1 Load and Line ............................................................................................ 18 9.5.2 Battery Load Charge Profile at 120VAC Input............................................ 18 10 Waveforms............................................................................................................ 19 10.1 Drain Voltage and Current, Normal Operation .................................................. 19 10.2 Output Voltage Start-up Profile ......................................................................... 19 10.3 Output Ripple Measurements............................................................................ 20 10.3.1 Ripple Measurement Technique ................................................................ 20 10.3.2 Measurement Results ................................................................................ 21 11 Conducted EMI ..................................................................................................... 22 12 Revision History.................................................................................................... 23 1 2 3 4
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. 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-56
UPS Battery Charger - LNK520
April 20, 2005
1 Introduction
This document is an engineering prototype report describing a +12V 400mA charger power supply. The power supply utilizes the LinkSwitch LNK520 device. The LinkSwitch integrates a 700V MOSFET, PWM controller, high-voltage start-up, thermal shutdown, and fault protection circuitry. This power supply is a cost effective replacement of linear transformer based power supplies with the additional features of universal input voltage range and high-energy efficiency. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
Figure 1 - Populated Circuit Board Photograph
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
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 Peak Output Power Efficiency Environmental Conducted EMI Safety Surge
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Symbol VIN fLINE
Min 85 47
Typ
Max 265 64 0.6
Units VAC Hz W V mV mA
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 POUT POUT_PEAK
12 400 4.8 4.8 75
5% 20 MHz bandwidth
W W %
Measured at POUT (4.8 W), 25 oC
TBD
kV
Surge Ambient Temperature TAMB 0
TBD 50
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
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
3 Schematic
Figure 2 - Schematic
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
4 Circuit Description
The circuit schematic shown in Figure 2 shows a design that provides a constant voltage / constant current (CV/CC) output characteristic from a universal input voltage range of 85 VAC-265 VAC. This design delivers 4.8 W with nominal peak power point voltage of 12 V and a current of 400mA. 4.1 Input EMI Filtering The bridge rectifier, D1-D4, rectifies the AC input and is smoothed by C1 and C2, with inductor L1 forming a -filter to attenuate differential mode conducted EMI. Resistor RF1 is a fusible, flameproof type, providing protection from primary-side short circuits and line surges and provides additional differential EMI filtering. The switching frequency of 42kHz allows a simple EMI filter to be used without the need for a Y capacitor while still meeting international EMI standards. Capacitors C1 and C2 are sized to maintain a minimum DC voltage of around 127 V at the minimum AC input voltage. Their ESR should also be as low as possible to reduce differential mode EMI generation. The value of L1 is selected to give acceptable differential mode EMI attenuation with a current rating to meet the RMS input current at low line (or acceptable temperature rise). Conducted emissions in this design are compliant with EN55022B / CISPR 22B and FCC B limits with no input Y1 safety capacitor. 4.2 LinkSwitch Primary and Output Feedback The LNK520P contains the necessary functions to implement start-up and auto-restart (output protection) operation, output constant voltage (CV) and constant-current (CC) control. When power is applied, high voltage DC appears at the DRAIN pin of LinkSwitch (U1). The CONTROL pin capacitor C5 is then charged through a switched high voltage current source connected internally between the DRAIN and CONTROL pins. When the CONTROL pin reaches approximately 5.6 V relative to the SOURCE pin, the internal current source is turned off. The internal control circuitry is activated and the high voltage MOSFET starts to switch, using the energy in C5 to power the IC. Diode D6 rectifies the output of the bias winding, which is then smoothed by C3 to provide a DC voltage to be fed to the CONTROL pin via R4. Resistor R3 is added to filter noise due to leakage inductance. The value of R4 is set such that, at the peak power point, where the output is still in CV regulation, the CONTROL pin current is approximately 2.2mA. As the output load is increased, the peak power point (defined by 0.5 x L x I2 x f) is exceeded. The output voltage and therefore primary side bias voltage reduce. The reduction in the bias voltage results in a proportional reduction of CONTROL pin current, which lowers the internal LinkSwitch current limit (current limit control).
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
Constant current (CC) operation controls secondary-side output current by reducing the primary-side current limit. The current limit reduction characteristic has been optimized to maintain an approximate constant output current as the output voltage and bias voltage is reduced. If the load is increased further and the CONTROL pin current falls below approximately 0.8mA, the CONTROL pin capacitor C5 will discharge and LinkSwitch will enter autorestart operation. Current limit control removes the need for any secondary-side current sensing components. Removing the secondary sense circuit dramatically improves efficiency, giving the associated benefit of reduced enclosure size. Diode D5, C4, R1, and R2 form the primary clamp network. This limits the peak DRAIN voltage due to leakage inductance. Resistor R2 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 improves radiated EMI and also improves CV regulation, especially at no load. A glass passivated diode should be used with specified recovery time. 4.3 Output Rectification Output rectification is provided by Schottky diode D7. The low forward voltage provides high efficiency across the operating range. Low ESR capacitor C6 achieves minimum output ripple and maximizes operating efficiency. 4.4 Output Feedback Resistors R6 and R7 divide down the supply output voltage and apply it to the reference pin of error amplifier U3. Shunt regulator U3 drives Optocoupler U2 through resistor R8 to provide feedback information to the U1 CONTROL pin. Capacitor C7 rolls off the gain of U3 and is sufficient to compensate the control loop of the power supply.
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
5 PCB Layout
Figure 3 - Printed Circuit Layout
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
6 Bill Of Materials
Item QTY Ref Des 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description 10uF, 400 V, Electrolytic, Low ESR, 2.9 C1 C2 Ohms, (10 x 20) 1uF, 50 V, Electrolytic, Gen. Purpose, (5 C3 x 11) C4 1nF, 1 kV, Disc Ceramic C5 1.0uF, 50 V, Ceramic, X7R 330uF, 35 V, Electrolytic, Very Low ESR, C6 38mOhm, (10 x 16) C7 100nF, 50 V, Ceramic, X7R D1 D2 D3 D4 800 V, 1 A, Rectifier, DO-41 1000 V, 1 A, Rectifier, Glass Passivated, D5 2 us, DO-41 600 V, 1 A, Fast Recovery Diode, 200 ns, D6 DO-41 D7 100 V, 1.1 A, Schottky, DO-41 L1 1mH, 0.15 A, Ferrite Core R1 200 k, 5%, 1/2 W, Carbon Film R2 100 R, 5%, 1/8 W, Carbon Film R3 200 R, 5%, 1/4 W, Carbon Film R4 7.5 k, 1%, 1/4 W, Metal Film R6 19.1 k, 1%, 1/4 W, Metal Film R7 4.99 k, 1%, 1/4 W, Metal Film R8 470 R, 5%, 1/8 W, Carbon Film 8.2 R, 2.5 W, Fusible/Flame Proof Wire RF1 Wound T1 EE16 Flyback Transformer U1 LinkSwitch, LNK520P, DIP-8B Opto coupler, 35 V, CTR 300-600%, 4U2 DIP 2.495 V Shunt Regulator IC, 2%, 0 to U3 70C, TO-92 Manufacturer UCC UCC Panasonic Panasonic UCC Panasonic Mfg Part Number KMX400VB10RM10X20LL KMG50VB1R0M5X11LL ECK-D3A102KBP ECU-S1H105KBB KZE35VB331MJ16LL ECU-S1H104KBB 1N4006 1N4007GP 1N4937 11DQ10 SBCP-47HY102B CFR-50JB-200K CFR-12JB-91R CFR-25JB-200R MFR-25FBF-7K50 MFR-25FBF-19K1 MFR-25FBF-4K99 CFR-12JB-470R CRF253-4 5T 8R2 Power Integrations Isocom, Sharp TI LNK520P ISP817D, PC817X4 TL431CLP
Tokin
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
7 Transformer Specification
7.1 Electrical Diagram
Figure 4 - Transformer Electrical Diagram
7.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-5 to Pins 6-7 Pins 1-2, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with Pins 6-7 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 5000H, -10/+10% 500 kHz (Min.) 250 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
7.3
Materials
Description 2 Core: EE16, PC40EE16 TDK - Al = 124nH/T Bobbin: Horizontal 10 pin Magnet Wire: #33 AWG Magnet Wire: #36 AWG Magnet Wire: #28 AWG Triple Insulated Wire: #32 AWG Tape: 3M 1298 Polyester Film (white) 2.2mils thick Varnish
Item [1] [2] [3] [4] [5] [6] [7] [8]
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
7.4
Transformer Build Diagram
Figure 5 - Transformer Build Diagram
7.5
Transformer Construction
Bobbin Preparation Core Cancel/Bias Basic Insulation Primary Basic Insulation Balance Shield Basic Insulation Secondary Winding Outer Wrap Final Assembly Pull pins 8-10 on bobbin [2] to provide polarization. Align bobbin on mandrill with pins 1-5 on right hand side. Starting on left hand side of bobbin, wind 34 turns of item [3] uniformly on a single layer from left to right. Finish winding on pin 4. Wrap start of wire to pin 5. Use two layers of item [7] for basic insulation. Start at Pin 2. Wind 50 turns of item [4] uniformly on a single layer from right to left. Apply one layer of tape, wind 50 turns on the secondary, third and fourth layer (200T total) adding 1 layer of tape [7] between each layers. Finish winding on pin 1. Use two layers of item [7] for basic insulation. Starting on left hand side of bobbin, wind 21 turns of item [5] uniformly on a single layer from left to right. Finish winding on pin 3. Wrap start of wire to right hand side of bobbin and cut close to start of winding leaving it unconnected (as shown in Figure 5). Use two layers of item [7] for basic insulation. Start at Pin 7. Wind 23 of item [6] uniformly on a single layer from left to right. Finish on Pins 6. Wrap windings with 3 layers of tape (item [7]). Assemble and secure core halves. Varnish impregnate (item [8]).
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
8 Transformer Spreadsheet
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1
80.00%
Efficiency at Full Load (400mA)
75.00%
70.00%
65.00%
60.00% Efficiency (%)
55.00%
50.00%
45.00%
40.00%
35.00%
30.00% 0 50 100 150 Input Voltage (VAC) 200 250 300
Figure 6 - Efficiency vs. Input Voltage, Room Temperature
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DER-56 9.2
90.00%
UPS Battery Charger - LNK520
April 20, 2005
Efficiency vs. Output Current
Vin = 85VAC Vin = 115VAC 80.00% Vin = 230VAC Vin = 265VAC
70.00%
60.00% Efficiency (%) 50.00%
40.00%
30.00%
20.00%
10.00%
0.00% 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Load Current (ADC)
Figure 7 - Efficiency vs. Output Load, Room Temperature
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DER-56 9.3
UPS Battery Charger - LNK520
April 20, 2005
Efficiency and Input Power Comparison to Transformer + LDO
100.00%
LNK520 Flyback (% eff) Linear Transformer (% eff)
40
90.00%
LNK520 Flyback Input Power Linear Transformer Input Power
36
80.00%
32
70.00%
28
Inpt Power (W)
60.00% Efficiency (%)
24
50.00%
20
40.00%
16
30.00%
12
20.00%
8
10.00%
4
0.00% 0 0.1 0.2 0.3 0.4 0.5 Load Current (ADC) 0.6 0.7 0.8 0.9 1
0
Figure 8 - Efficiency and Input Power at 120VAC Input, Room Temperature, 60 Hz.
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DER-56 9.4
1
UPS Battery Charger - LNK520
April 20, 2005
No-load Input Power
0.9
0.8
0.7
0.6 Input Power (W)
0.5
0.4
0.3
0.2
0.1
0 0 50 100 150 Input Voltage (VAC) 200 250 300
Figure 9 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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DER-56 9.5 Regulation
UPS Battery Charger - LNK520
April 20, 2005
9.5.1 Load and Line
14.00
Vin = 90VAC Vin = 120VAC Vin = 240VAC Vin = 265VAC
12.00
Output Voltage (VDC)
10.00
8.00
6.00
4.00
2.00
0.00 0.00
0.20
0.40
0.60 Load Current (ADC)
0.80
1.00
1.20
Figure 10 - Load Regulation, Room Temperature.
9.5.2 Battery Load Charge Profile at 120VAC Input
20 19 18 17 16 15 14 13 Battery Voltage (VDC) 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0.1 0.2 0.3 0.4 Charge Current (ADC) 0.5 0.6 0.7 0.8 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% Efficiency (%) 70.00% 80.00% 90.00% 100.00%
Figure 11 - Battery Charge Profile, Room Temperature.
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
10 Waveforms
10.1 Drain Voltage and Current, Normal Operation
Figure 12
- 85VAC, Full Load
Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 100 V, 10 s / div
Figure 13
- 265VAC, Full Load
Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 200 V / div
10.2 Output Voltage Start-up Profile
Figure 14 - Start-up Profile Vin = 115VAC; 12V @ 400mA, 2 V, 50 ms / div.
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
10.3 Output Ripple Measurements 10.3.1 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 15 and Figure 16. 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 15 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 16 - 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-56
UPS Battery Charger - LNK520
April 20, 2005
10.3.2 Measurement Results
Figure 17 - Ripple, 120VAC, Full Load. 50 s, 200 mV / div
Figure 18 - Ripple, 120VAC, Full Load. 2 ms, 200 mV / div
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
11 Conducted EMI
Figure 19
- Conducted EMI, Maximum Steady State Load, 115VAC, 60 Hz, and EN55022 B Limits
Figure 20 - Conducted EMI, Maximum Steady State Load, 230VAC, 60 Hz, and EN55022 B Limits
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
12 Revision History
Date April 20, 2005 Author RSP/EC Revision 1.0 Description & changes Initial release Reviewed KM / JC / AM
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DER-56
UPS Battery Charger - LNK520
April 20, 2005
For the latest updates, visit our Web site: 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, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
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