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Design Example Report
Title Specification Application Author Document Number Date Revision 3.6W Charger using TNY266P Input: 85 - 264 VAC Output: 5.1V / 700mA Cell Phone Charger Power Integrations Applications Department DER-6
February 4, 2004 1.0
Summary and Features
* * * * Low Cost CVCC charger Low Parts Count Meets EMI with no Y-capacitor No load power consumption < 300 mW @ 230 Vac
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-6
3.6W Cell Phone Charger
February 4, 2004
Table Of Contents
Introduction................................................................................................................. 3 Power Supply Specifications ...................................................................................... 3 Schematic................................................................................................................... 4 PCB Layout ................................................................................................................ 4 Bill of Material............................................................................................................. 5 Power Supply Performance........................................................................................ 6 6.1 Output Characteristic........................................................................................... 6 6.1.1 V-I curve at different Input Voltages ............................................................. 6 6.1.2 V-I Curve at Different Temperatures ............................................................ 7 6.2 Efficiency............................................................................................................. 7 6.2.1 Efficiency vs. Input voltage........................................................................... 7 6.2.2 Efficiency vs. Output current ........................................................................ 8 6.3 Output Ripple. ..................................................................................................... 8 6.4 Transient Load Response ................................................................................... 9 6.5 No load power consumption................................................................................ 9 7 Conducted EMI Measurement.................................................................................. 10 8 Transformer Design.................................................................................................. 12 8.1 Transformer Winding......................................................................................... 12 8.2 Electrical Specifications..................................................................................... 12 8.3 Materials............................................................................................................ 12 8.4 Transformer Construction.................................................................................. 13 8.5 Winding Instructions .......................................................................................... 14 9 Revision History ....................................................................................................... 15 1 2 3 4 5 6
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-6
3.6W Cell Phone Charger
February 4, 2004
Introduction.
This document describes the design for a 5.1V 700mA battery charger. The design is implemented using a TNY266 controller with an EF16 transformer in a flyback topology. This report includes the design specifications, performance, transformer design, and bill of materials.
1 Power Supply Specifications
The following table shows the supply specifications.
Description Input Voltage Frequency Output Output Voltage Output Ripple Voltage Output Current Total Output Power Continuous Output Power Ambient Temperature Symbol VIN fLINE VOUT VRIPPLE IOUT POUT TAMB Min 85 50/60 5 650 700 3.64 0 50 5.2 60 750 Typ Max 264 Units VAC Hz V mV A W C Comment
2 wire, no protective earth
20 MHz Bandwidth
o
Free convection, Sea level
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DER-6
3.6W Cell Phone Charger
February 4, 2004
2 Schematic
C8
4
R9 10 D4 D5
N/U
+
L1
1
. . . .
T1
8 7
1nF
R3 1.68
L3 Bead
+
1.0 mH
2
SR206
J2-1
C9 220uF 10V R10 0.33
D1 1N4005 J1-1
RF1
D2 1N4005
C1 1nF 1KV
R1 200K
Floating
3
C3 470uF 10V
J2-2
8.2 Fusible
+
C4 4.7uF 400V
R2 100
85V-265V AC C5 4.7uF 400V J1-2
D EN
+
2
R5 1K D3 1N4007G
U2B
R4 100 R7 10K 1% R8 9.53K 1%
1
C6 JP1 U2A LTV817A C7 0.1uF
3 4
U1 D6 1N4005 D7 1N4005 L2 N/U
S
BP
U3 TL431
0.1uF
TNY266P
Figure 1 - Schematic
3 PCB Layout
Figure 2 PCB layout Notes: C11, D8, R12 are optional for a bias supply to further reduce no-load consumption.
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DER-6
3.6W Cell Phone Charger
February 4, 2004
4 Bill of Material
Item 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 Quantity Reference 2 1 1 1 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 C4, C5 C1 C3 C9 C6, C7 C8 D1, D2, D6, D7 D3 D4 L1 L3 RF1 R1 R2 R3 R4 R5 R7 R8 R9 R10 T1 U1 U2 U3 Part Description 4.7uF 400V, Electrolytic 1nF 1KV, Ceramic Disk 470uF, 10V, Low ESR 220uF, 10V, Low ESR 0.1uF, 50V, Ceramic 1nF 100V, Ceramic 1N4005, 1Amp, 600V 1N4007G, 1A, 1KV, Glass Passive. SR206, 2A, 60V, Schottky 1mH, Inductor Ferrite Bead 8.2 Ohm, 1W, Fusible Resistor 200K, 1/2W 100, 1/4W 1.68, 2W 100 1/8W 1K, 1/8 10.0K 1%, 1/8W 9.53K 1%, 1/8W 10, 1/4W 0.33, 1W EF16 Custom Transformer TNY266P LTV817A TL431, 2.5V Reference
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DER-6
3.6W Cell Phone Charger
February 4, 2004
5 Power Supply Performance
Note: All measurements were made at the end of the output cable with a resistance of 0.25 . 5.1 Output Characteristic.
5.1.1 V-I curve at different Input Voltages
Output Characteristic
6 5 Output Voltage (DC) 4 3 2 1 0 0 100 200 300 400 500 600 700 800 Output Current (mA) Vin115VAC Vin230VAC
Figure 3 Typical output characteristic
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DER-6
3.6W Cell Phone Charger
February 4, 2004
5.1.2 V-I Curve at Different Temperatures The data was taken at 115Vac, in a small box, with no airflow
V-I Characteristic vs Temp.
5.5 5 Output Voltage (Vdc) 4.5 4 3.5 3 2.5 2 1.5 0 100 200 300 400 500 600 700 800 Output Current (mA) 0C 25 C 40 C lower limit upper limit
Figure 4 Output Characteristic at different temperatures 5.2 Efficiency
5.2.1 Efficiency vs. Input voltage
Efficiency Vs Line Voltage
70 60 Output Efficiency (%) 50 40 30 Iout=685mA 20 10 0 80 100 120 140 160 180 200 220 240 260 280 Input Voltage (AC)
Figure 5 - Efficiency vs. input voltage
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DER-6
3.6W Cell Phone Charger
February 4, 2004
5.2.2 Efficiency vs. Output current
Efficiency Vs Load Current
70 60
Output Efficiency (%)
50 40 30
Vin115VAC
20 10 0
Vin230VAC
0
100
200
300
400
500
600
700
800
Output Current (mA)
Figure 6 - Efficiency vs. output current 5.3 Output Ripple. The output Ripple was measured in the input voltage range from 85 to 265VAC and output load current range from 0 to 640mA. The picture below shows the worst case.
Figure 7 - Output ripple measure at Vin=85Vac, Iout=640mA
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DER-6 5.4
3.6W Cell Phone Charger
February 4, 2004
Transient Load Response
Figure 8 - Output ripple measure at Vin=85Vac, Iout step from 350mA to 685mA 5.5 No load power consumption
No Load Power Consumtion
350 300 Input Power (mW) 250 200 150 100 50 0 80 100 120 140 160 180 200 220 240 260 280 Input Voltage (AC)
Figure 9 - No load power consumption
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DER-6
3.6W Cell Phone Charger
February 4, 2004
6 Conducted EMI Measurement
Conducted EMI was measured and compared with EN22B limits. The measured results are shown below.
Figure 10 - Measured conducted EMI. Input 115V; output5.1V 650mA; output return connected to the ARTIFICIAL HAND CONNECTOR of the LISN detection mode: QuasiPeak and Average; Phase: Line and Neutral
Figure 11 - Measured Conducted EMI. Input 115V; Output5.1V 650mA; Output floating; Detection Mode: Quasi-Peak and Average; Phase: Line and Neutral
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DER-6
3.6W Cell Phone Charger
February 4, 2004
Figure 12 - Measured Conducted EMI. Input 230V; Output5.1V 650mA; Output return connected to the ARTIFICIAL HAND CONNECTOR of the LISN Detection Mode; QuasiPeak and Average; Phase: Line and Neutral
Figure 13 - Measured Conducted EMI. Input 230V; Output5.1V 650mA; Output floating; Detection Mode: Quasi-Peak and Average; Phase: Line and Neutral
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DER-6
3.6W Cell Phone Charger
February 4, 2004
7 Transformer Design
7.1 Transformer Winding
4
WD#1
21T # 33 AWG X 2
1 Floating 8
WD#4 7 T # 28 TIW X 2 Secondary
7
WD#3
6T #28X4
3 1
Primary WD#2 88 T #34 AWG
2
Figure 14 - Transformer Winding
7.2
Electrical Specifications
Electrical Strength Primary Inductance (Pin 1 to Pin 2) Resonant Frequency. (Pin 1 to Pin 2) Primary Leakage Inductance. (Pin 1 to Pin 2) 60Hz 1minute, from Pins 1-4 to Pins 7-8 All windings open All windings open Pins 7-8 shorted 3000 V ac 937 uH +/- 10% at 132KHz 950 kHz (Min.) 37 uH Max.
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description 2 Core: PC40EF16-Z, TDK or equivalent Gapped for AL of 122 nH/T Bobbin: Horizontal 8 pin. Pin 5 and 6 to be removed. Magnet Wire: #34 AWG Magnet Wire: #33 AWG Magnet Wire: #28 AWG Triple Insulated Wire: #28 AWG. Tape: 3M 1298 Polyester Film, 2.0 mils thick, 9.8 mm wide Tinned bus wire 32 AWG Varnish
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DER-6 7.4
3.6W Cell Phone Charger
February 4, 2004
Transformer Construction
Tape
7 8 Floating 3
Secondary Tape Shield Tape
1 2
Primary Tape
4 1
Shield
Figure 15 - Transformer construction
Bring the starting lead to the end of the bobbin's winding window on the primary side and cut the lead right here
Floating 3
WD #3
1 2 4 1
Figure 16 - Partial Transformer Winding Diagram showing the place where the starting lead of winding 3 should be cut
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DER-6
3.6W Cell Phone Charger
February 4, 2004
7.5
Winding Instructions
WD1 Shield Winding WD1 Insulation WD#2 Primary winding Insulation WD #3 Shield Winding WD #3 Insulation WD #4 Secondary Winding Outer Insulation Core Assembly Core Grounding Varnish Primary pin side of the bobbin oriented to left hand side. Start at Pin 7 temporarily. Wind 21 bifilar turns of item [4] from right to left. Wind with tight tension across entire bobbin evenly. Finish on Pin 1. Change the start pin from pin 7 to pin 4. 2 Layers of tape [7] for insulation. Start at pin 2 wind 44 turns of item [3] from left to right, then wind another 44 turns next layer from right to left. Wind with tight tension across entire bobbin evenly Finish at pin 1 2 Layers of tape [7] for insulation. Start at Pin 7 temporarily, wind 6 quadrifilar 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 3. Cut the lead of the starting end as in shown in figure 15. 2 Layers of tape [7] for insulation. Start at pin 8, wind 7 bifilar turns of item [6] from right to left. Wind uniformly, in a single layer across entire bobbin evenly. Finish on pin 7. 3 Layers of tape [7] for insulation. Assemble and secure core halves. Start at Pin 3, wind 2 turns of [8], around the core close to primary side. Finish at pin 3. Wind it tight making good contact the wire with the core. Varnish
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DER-6
3.6W Cell Phone Charger
February 4, 2004
8
Revision History
Date February 4, 2004 Author YG Revision 1.0 Description & changes Initial release Reviewed AM/VC
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DER-6
3.6W Cell Phone Charger
February 4, 2004
Notes
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DER-6
3.6W Cell Phone Charger
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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