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| power integrations 5245 hellyer avenue, san jose, ca 95138 usa. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com title engineering prototype report for ep-73 - 2.3 w cv/cc charger/adapter using linkswitch ? -hf (lnk354p) specification 85-265 vac input, 5.7 v, 400 ma output application low cost charger or adapter author power integrations applications department document number EPR-73 date 25-oct-04 revision 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) toleranc e: 12% across operating range ? meets en550022 and cispr-22 class b em i 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 comp lete list of power integrations? patents may be found at www.powerint.com .
ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 table of contents 1 introducti on ................................................................................................................. 3 2 power supply s pecificat ion ........................................................................................ 4 3 schemat ic ................................................................................................................... 6 4 circuit desc ription ...................................................................................................... 7 4.1 input emi f iltering ............................................................................................... 7 4.2 linkswitch- h f primary ........................................................................................ 7 4.3 output rectif ication ............................................................................................. 7 4.4 output f eedback ................................................................................................. 7 4.5 design aspect s for em i ....................................................................................... 8 5 pcb lay out ................................................................................................................ 9 6 bill of ma te rials ........................................................................................................ 10 7 transforme r spec ificatio n ......................................................................................... 11 7.1 electrical diagram ............................................................................................. 11 7.2 electrical spec ifications ..................................................................................... 11 7.3 material s ............................................................................................................ 11 7.4 transforme r build diagram ............................................................................... 12 7.5 transforme r cons tructi on .................................................................................. 12 8 transforme r desi gn spreads heet ............................................................................. 13 9 performanc e data .................................................................................................... 16 9.1 efficienc y ........................................................................................................... 16 9.2 no-load input power .......................................................................................... 17 9.3 regulati on ......................................................................................................... 17 9.3.1 cv and cc output c haracterist ics ............................................................. 17 9.3.2 load regulation in cv ............................................................................... 18 10 thermal perf ormance ........................................................................................... 19 11 line surg e ............................................................................................................. 20 12 wavefo rms ............................................................................................................ 21 12.1 drain voltage and cur r ent, normal oper ation ................................................... 21 12.2 output voltage star t-u p pr ofile .......................................................................... 22 12.3 drain voltage and cur r ent start-u p profile ........................................................ 22 12.4 load transient response ( 75% to 100% load step ) ....................................... 23 12.5 output ripple m easurement s ............................................................................ 24 12.5.1 ripple measurement t e chnique ................................................................ 24 12.5.2 measurement result s ................................................................................ 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 hist ory .................................................................................................... 33 important note: although this board is designed to satisfy safe ty isolation requirem ents, the engineering prototype has not been agency approved. ther efore, all testing should be per formed using an is olation transforme r to provide the ac input to the prototype board. page 2 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 1 introduct i on this document is an engineerin g report describing a 5.7 v, 400 ma power supply utilizing a lnk354p device. this po wer supply is intended as a gene ral purpos e evaluation platform fo r linkswitc h -hf dev ic es in a bat tery charger applic ation with s e c o ndary side cv/cc con t rol. the document contains the power supply spec ific ation, schematic, bill of materials, transformer documentation, printed ci rcuit layout, and performance data. figure 1 ? ep73 populate d circuit board photograph . page 3 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 2 power supply s p ecificatio n des c ription sy mbol min ty p max units c o mment input voltage v in 8 5 2 6 5 v a c 2 wire ? no p.e. freq uen cy f line 4 7 5 0 / 6 0 6 4 h z no-l oad inp u t power (230 vac) 0.3 w outpu t output voltag e 1 v out1 5 . 2 5 . 7 6 . 3 v 5% output rip p le voltage 1 v ripple 1 1 0 0 m v 20 mhz band w i d t h output cu rre n t 1 i out1 3 5 0 4 0 0 4 5 0 m a with batter y m o d e l attached to end of output ca ble, measured at 25 c total ou tpu t po w e r contin uou s o u tput powe r p out 1 . 8 2 2 . 3 2 . 8 * w efficiency 5 5 % measured at p ou t (1.8 w), 230 vac, 25 o c en v i ronmental c o nd uc te d emi meets cispr22 b / en55022b > 6 db margin s a f e t y designed to mee t iec950, ul1 9 5 0 class ii s u r g e 2 k v 1.2/50 s surge, iec 1000-4 - 5, series impedance: differential mode : 2 ? common mode: 12 ? s u r g e 2 k v 100 khz ring w a v e , 500 a short circuit current, differential and common mode ambient tem peratu r e t am b 0 5 0 o c free convection, sea level * maximum output power of the lnk354 is r e stri cted by enclosure size ? higher powers are possible with larger enclo sures and pcb heatsink area. page 4 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 0 1 2 3 4 5 6 7 0 0 . 0 5 0 . 1 0. 15 0. 2 0 . 2 5 0 . 3 0. 35 0. 4 0 . 4 5 0 . 5 o u tput c u r r e nt (a ) out put vol t age ( v ) figure 2 ? o u tput cv/cc envelope sp ecification. page 5 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 3 schematic figure 3 ? ep73 schem atic. page 6 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 4 circuit descriptio n this circu i t is configu r ed as a flyback top o logy p o wer supply utiliz ing th e lnk 354 p. secondary side cons tant volt age (cv) and constant current (cc) feedback circuitry provides characteristics required for battery charging applications. 4.1 input em i filtering the ac input voltage is rectified by input bridge d1 ? d4. the rectified dc is then filter ed by the bulk storage capacitors c1 and c2. inductor l1, c1 and c2 form an i nput pi filter, which attenuates differential mode conducted emi. it is recommended that rf1 be of wire-wound const r uction to withstand input current surges while the input capacitor c harges (metal film type are not recommended), and be compliant with safety flammability hazard r equirements. please consult your safety agency representative for requirements specific to your application. 4.2 linkswitch-hf primary the lnk354p devic e u1 integrates the power switching device, oscillator, control, startup, and protection functions. the int egrated 700 v mosfet has excellent switching characteristics allowing operatio n at the 200 khz operating frequency. the rectified and filtered input voltage is ap plied to the primary windi ng of t1. the other side of the transformer primary is driven by the integrated mo sfet in u1. diode d5, c3, r1, r2, and r3 form the primary clamp net work . this limits the pe ak drain voltage due to leakage inductance. resistor r3 allows t he 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 improv es conducted emi. to regulate the output, on/off control is us ed. during normal operat ion, switching of the power mosfet is disabled when a current greater than 49 a is d e liv ered into the feedback pin. curr ent lower than this threshold allo ws a s witching cy cle to occ u r terminating when the peak primary current reaches the internal current limit. current into the feedback pin is fed, via optoco upler u2, from the bypass pin removing the need for an auxiliary bias winding on the transformer. 4.3 output rectification output rectification is prov ided by schottky diode d6. the low forward voltage provides high efficiency across the operating range. low esr capacitor c6 achiev es minimum output voltage ripple and nois e 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 v be of q1 divided by the value of r7 sets page 7 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m 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 det ermined by q1 and vr1, q1 is tur ned on and current flows through the led of u2. as the led current increas es, the curr ent fed into the feed back pin increase s disabling further switching cycles of u1. at very light loads almost all switching cycles wi ll be disabled, giving a low effective swit ching frequency and providing low no-load consumption. resistors r6 and r8 ensure that the ratings of q1 ar e not exceeded during load transients. resistors r9 and r10 form the c onstant current (cc) sense ci rcuit. above approximately 400 ma, the voltage across the sense resist or exceeds the optocoupler diode forward conduction voltage of approximately 1 v. the current through the led is therefore determined by the output cu rrent and cc control dominat es the cv feedback loop. 4.5 design aspects for em i in addition to the simple input pi filter for differential mode emi, this design makes use of shielding t e chniques in the transforme r to reduce common mode emi displac e ment currents. resistor r5 and c5 are added to act as a damping network to reduce hig h frequency transformer ringing. to return high frequency common mode dis p lace ment currents, a sm all v a lue (100 pf) y1 safety c apacitor is placed acr o ss the is olation barrier. th is is a small enough value t o still meet the design re quirement of low leak age current. these techniques combined with the frequency jitter of linkswitch-hf giv e excellent conducted and radiated emi performance. page 8 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 5 pcb la yout figure 4 ? printed circuit l a yout (appr o x imately 1.2 x 1.8 inche s ). page 9 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 6 bill of materials item qn t y ref. de s. value descrip tion mfg part nu mbe r manu fact urer 1 2 c1, c 2 4.7 f 4.7 f, 400 v, el ectrol y t ic, (8 x 11 .5) 4.7 f, 380 v, el ectrol y t ic, (8 x 11 .5) shd400wv 4.7u f xx380vb4r7m8 x11ll sam y o u ng united chemi-c o n 2 1 c3 2.2nf 2.2 nf, 40 0 v, film 222237065 222 vishay (bc components) 3 1 c4 100 nf 100 nf, 50 v, ce ramic, x7r, 080 5 ecu-v1h2 21kb n panasonic 4 1 c5 2.2 nf 2.2 nf, 50 v, cer a mic, x7r, 0805 ecj-2vb1h222 k panasonic 5 1 c 6 330 f 330 f, 16 v, el ectrol y t ic, very l o w es r, 72 m ? , (8 x 11 .5 ) kze16vb331mh 1 1 l l n i p p o n chemi- c o n 6 1 c y 1 100 pf 100 pf, c e ramic, y 1 440lt10 vishay 7 4 d1, d2, d3, d4 1n4005 600 v, 1 a, rectifier, do-41 1n4005 vishay 8 1 d 5 d l 4 0 0 7 1000 v, 1 a, rec t ifier, glass passivated, do -213aa (mel f) d l 4 0 0 7 d i o d e s i n c 9 1 d6 ss14 40 v, 1 a, schott k y , do-214ac ss14 vishay 1 0 2 j 1 , j 2 pcb terminal 22 awg pcb terminal hole, 22 awg n/a n/a 1 1 1 j 3 output cable assembly 6 ft, 0.25 ? , 2.1 mm connector (c ustom) 3ph243 anam instrument s (korea ) 1 2 3 jp1, jp2, jp3 j wire jumper, no n insulated, 22 awg, 0.4 in 298 alpha 13 1 l1 1 mh 1 mh, 0.15 a, fe rrite cor e sbcp-47h y 102 b tokin 14 1 q1 mmst3906 pnp, small signal bjt, 40 v, 0.2 a, sot- 323 mmst3906- 7 diodes inc 1 5 2 r1, r 2 47 k ? 4 7 k ? , 5%, 1/ 8 w, metal film, 0805 erj-6ge y j473 v p a n a s o n i c 1 6 2 r3, r 9 200 ? 2 0 0 ? , 5 % , 1/8 w, metal film, 0805 erj-6ge y j201 v p a n a s o n i c 1 7 1 r 4 5.1 k ? 5 . 1 k ? , 5%, 1 / 8 w, metal film, 0805 erj-6ge y j512 v p a n a s o n i c 1 8 1 r 5 68 ? 6 8 ? , 5 % , 1/8 w, metal film, 0805 erj-6ge y j680 v p a n a s o n i c 1 9 1 r 6 6.8 ? 6 . 8 ? , 5 % , 1/8 w , metal film, 0805 erj-6ge y j6r8 v p a n a s o n i c 2 0 1 r 7 220 ? 2 2 0 ? , 5 % , 1/8 w, metal film, 0805 erj-6ge y j221 v p a n a s o n i c 2 1 1 r 8 390 ? 3 9 0 ? , 5 % , 1/8 w, metal film, 0805 erj-6ge y j391 v p a n a s o n i c 2 2 1 r 1 0 2.4 ? 2 . 4 ? , 5 % , 1 w, metal oxide rsf100jb-2 r 4 y age o 2 3 1 r f 1 8.2 ? 8 . 2 ? , 2.5 w, fu sible/flame-proo f wire-wound crf253 -4 5 t 8r 2 vitrohm 2 4 1 t 1 e e 1 6 c u s t o m sil6032 lsla40331b im 040 416 11 hical li shin vogt 2 5 1 u 1 l n k 3 5 4 p linkswitch-hf , l n k354p, dip-8b lnk354p power integ r atio ns 26 1 u2 pc817d optocoupler, 80 v, ctr 30 0-600 %, 4-d i p pc817x4, ipc81 7 d sharp, isp 27 1 vr1 bzx79-b5v1 5.1 v, 500 mw, 2%, d o -35 bzx79-b5v1 vishay page 10 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 7 t r ansformer s p ecification 7.1 electrical diagram 9 t 25 aw g t .i. w. 28 t 2 x 3 7 aw g flo a tin g 5 n/c 9 8 6 t 4 x 2 8 aw g n/c 4 114 t 34 aw g 3 5 w i ndi ng #1 w i ndi ng #3 w i ndi ng #2 w i ndi ng #4 figure 5 ? transfo rme r electri c al di ag ram. 7.2 electrical specifications electrical str e ngth 60 hz 1 minu te, from pins 3-5 to pins 6 - 10 3000 vac primar y indu ctan ce pins 3-5, all other win d ing s open, mea s u r ed at 200 khz, 0.4 vrms 916 h, -/+12 % reso nan t fr equen c y pins 3-5, all other win d ing s open 900 khz (min .) primar y leakage induc ta nce pins 3-5, with pins 8-9 sho r ted, mea s ured at 200 khz, 0.4 vrms 75 h (max .) 7.3 m a t e rials i t e m d e s c r i p t i o n [1] core: pc40e e16-z, tdk o r equivale nt gapp ed for a l of 70 nh/t 2 [2] bobbin: ee16 hori zontal 1 0 pin [3] magnet wire: #37 awg [4] magnet wire: #34 awg [5] magnet wire: #28 awg [6] triple in sulat ed wire: #25 awg. [7] tape: 3m 12 98 polyeste r film, 2.0 mils thick, 8.4 m m wide [8] varnis h page 11 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 7.4 transformer build diagram float ing flo a tin g 5 prim ary win d i n g s e c onda ry wi n d i n g shield 4 la y e r s of tape ca n cella t i on win d i n g 3 4 8 9 5 figure 6 ? transfo rme r bu ild diag ram. 7.5 transformer construction first windin g - canc ellation primary pin si de of the bob bin orie nted to left-hand si de. start at pin 8 temporarily. wind 2 8 bifila r turn s of it em [3] from right to left. wind with tight tension across enti r e bobbi n evenl y and leave the finish e nd free. bend the free end 90 a nd dra w the wi re acro ss the b obbin windo w cutting in the cente r of the bobbi n. move start en d of windi ng from pin 8 to pin 5. insulation 4 layers of tape [6] for insu lation. second win d ing - primar y start at pin 3 wind 3 8 turn s of item [4] from left to right. add one layer of tape. wind another 38 turns from ri ght to left. add o ne layer of tape. wind 38 turns in third layer from le ft to right. wind with tight tens ion across enti r e bobbi n evenl y. finish at pin 5. insulation 2 layers of tape [6] for insu lation. third windin g - shield start at pin 8 temporarily, wind 6 q uadfil ar turn s of item [5]. wind from right to left with tight tensio n in a singl e uniform laye r across enti r e width of bobbin. finish o n pin 4. cut star t en d at pin 8 ensuring u n iformi ty of windi ng and t ape do wn in place. insulation 2 layers of tape [7] for insu lation. fourth wind ing start at pin 9, wind 9 turns of item [6] fro m right to left. wind uniformly, in a singl e layer acro ss entire bobbin width . finish on pi n 8. outer insulation 3 layers of tape [7] for insu lation. core ass e m b ly a sse mble a n d se cur e co re halv e s. varnish dip varnish [8] ? d o n ot v acuum i mp r e gnate page 12 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 8 t r ansformer design s p readsheet a cdc _l i n k s w i t c h - hf_0609 04; re v 1 -1; cop y ri ght po w e r integr atio ns i n c . 2004 i n p u t i n f o outp ut u n i t a c d c _ l inks w i t c h-h f _0609 04_ re v 1 -1.x ls; link s w itch- tn_h f co nti n u ous/di sco ntin u ous fl y b ac k tra n sfor mer desig n sprea d s h eet enter a p plica t i o n v a ri a b les vacmin 85 volts minimum ac input voltage vacmax 265 volts maximum ac inp u t voltage fl 50 hertz ac mains frequ enc y vo 5.7 volts output voltage io 0.4 amps power suppl y output cur r ent cc th reshold vo ltage 1.04 volts voltage drop acr o ss sense resist or . fo r cv onl y circuits enter "0" po 2.696 watts output po wer n 0.57 efficiency estimate. for cv onl y d e signs enter 0.7 if no better data available z 0.75 loss allocat i on factor tc 3 mseconds bridge rectifier conduction time estimate cin 9.4 ufarads input capacitanc e enter li nksw i t ch- h f v a r i a b les linksw itch-hf l n k 3 5 4 u n i v e r s a l 1 1 5 doubled/23 0 v chosen device lnk354 power out 4.5 w 5 w ilimitmin 0.233 amps minimum current limit i l i m i t m a x 0.268 amps max i mum cu rren t limit f s 186000 hertz minimum device sw itching fr equ enc y fs full load 178750 1 7 8 7 5 0 h e r t z maximum s w itching freque nc y at f u ll load and lp min. for max i mum po wer capability ente r 1 86 khz (fs_min), reducing this value w ill reduce emi but lo w e r po w e r capability vo r 91 91 volts reflected outp ut voltage vds 10 volts linksw itch-hf o n -state drain to source voltage vd 0.45 0.45 volts output winding diode for w ard v o ltage drop k p 1.15 ripple to peak current ratio (0.6 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 3r d output vo3 v o l t s outpu t volta g e io3 amps out p ut dc current p o 3 0.00 w a t t s outpu t pow e r vd3 volts outpu t diod e forw ard vol t age drop ns3 0.00 outpu t w i n d ing nu mber of turn s isrms3 0.000 amps outpu t w i n d ing rm s curren t irippl e 3 0 . 0 0 a m p s outpu t capa ci tor rms ripple cur r ent pivs3 0 volts outpu t re ctifie r ma x i mum peak inv e rse vol t age cms3 0 cmils outpu t w i n d ing bar e condu ctor minim u m cir c ula r mil s aw gs 3 n/ a aw g w i re gaug e (roun ded up to nex t lar g er stand ard a w g v a lue) di as3 n/ a mm minimum bare con duc tor diame t er ods3 n/ a mm max i mu m outs ide diamet er f o r triple i n s u lat e d w i re total po w e r 2.696 w a tts total o u tpu t pow e r page 15 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 9 performance dat a all measur ements performed at room temperature, 60 hz i nput frequency. a dc outp ut cable was not included. 9.1 efficiency figure 7 ? efficiency vs. output cu rre nt (cv), roo m tempe r atu r e, 60 hz. 40 % 45 % 50 % 55 % 60 % 65 % 0 0 . 0 5 0 . 1 0. 15 0. 2 0 . 2 5 0 . 3 0. 3 5 0. 4 0 . 4 5 ou t p u t lo a d ( a ) efficien cy 90 v a c 11 5 v a c 23 0 v a c 26 5 v a c page 16 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 9.2 no-load input power 0 0. 05 0. 1 0. 15 0. 2 0. 25 0. 3 50 10 0 1 50 200 2 5 0 3 00 in pu t v o lt a g e ( v a c ) i nput power (w) figure 8 ? zero l o a d input powe r vs. input lin e voltage, ro om tempe r at ure, 60 hz. 9.3 regulation 9.3.1 cv and cc output characteristics no measurable difference was seen over line voltage variation. 0 1 2 3 4 5 6 7 0 0 .05 0 .1 0 . 15 0.2 0 .2 5 0 .3 0.3 5 0 . 4 0 .4 5 0 .5 out put c u rrent ( a ) output voltage (v) figure 9 ? cv/cc o u tp ut characte ri stic with spe c if ication limit s added, roo m tempe r atu r e. page 17 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 9.3.2 load regulation in cv 4 4. 5 5 5. 5 6 6. 5 7 0 0 . 0 5 0 . 1 0.15 0.2 0 . 2 5 0 .3 0.35 0.4 o u t p ut lo a d ( a ) output volta g e (v) figure 10 ? l oad regulati on in cv ope r ation, ro om tempe r atu r e, full load. page 18 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 10 thermal performance temperature of key com ponents was recorded using a t-type thermocouple. thermocouples were soldered directly to lnk354 p source pin and cath ode of out put rectifier. thermocouples were glued to the output capacitor and transformer external core/winding surfaces. the unit was operated at full load in free conv ection in a thermal chamber inside a n additional enclosure to elimin ate airflow. the ambient wa s measured in the additional enclosure and maintained at 40 c. tempera t ure ( c) item 85 vac 265 vac am bient 4 0 4 0 lnk354p (u1) 9 4 9 6 trans f ormer (t1) 8 0 8 2 outpu t recti f ier (d6) 6 7 6 4 outpu t c a pa citor ( c 6 ) 6 0 5 8 for reference an infrared thermograph was tak en with the unit operating at room ambient showing the relative temperature ri se of the key supply component s . figure 11 ? infrared the r mograph of pcb (85 vac, room ambi e n t). page 19 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 11 line surge surge voltage phase angle gener a tor impedance number o f strikes test resul t 2 kv 90 2 ? 1 0 p a s s 2 kv 90 12 ? 1 0 p a s s page 20 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 12 w aveforms 12.1 drain voltage and current, normal operation figure 12 ? 1 15 vac, full load. upp e r: i drain , 0.1 a / div. lower: v drain , 50 v, 200 ns / div. figure 13 ? 2 30 vac, full load. upp e r: i drain , 0.1 a / div. lower: v drain , 100 v, 100 ns / div. figure 14 ? 1 15 vac, full load. v drain , 50 v, 20 s / div. figure 15 ? 1 15 vac, full load. v drain , 100 v, 20 s / div. page 21 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m 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 wa s verified. load resistor was sized at 13 ? to maintain 300 ma under steady-state conditions. figure 16 ? start-up profile115 vac. fast tra c e is no load ri se ti me. slowe r trace is maximum l oad (1 3 ? ) 1 v, 2 ms / div. figure 17 ? start-up profile 230 vac. fast tra c e is no load ri se time. slowe r trace is maximum load (1 3 ? ) 1 v, 2 ms / div. 12.3 drain voltage and current start-up profile figure 18 ? 9 0 vac input and maximu m load (re s i s tive lo ad). upp e r: 200 v & 500 s/ div. lower: v drain , i dr ain , 0.1 a / div. figure 19 ? 2 65 vac input and maximu m load (re s i s tive lo ad). upp e r: 200 v & 500 s/ div. lower: v drain , i dr ain , 0.1 a / div. page 22 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 12.4 load tran sient response (75 % to 100 % load step) figure 20 ? tran sie n t re spo n se, 115 vac, 75-1 0 0 - 75% load step. upper:. v out 20 mv, 1 ms / div. lower: i out , 0 . 1 a / div . figure 21 ? tran sie n t re spo n se, 230 vac, 75-1 0 0 - 75% load step. upp e r: v out , 20 mv, 1ms / div. lower: i out , 0 . 1 a / div . page 23 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 12.5 output ripple m easurements 12.5.1 ripple measurement technique for dc out put ripple measurements, a modifi ed osc i lloscope tes t probe must be utiliz ed in order to reduce spurious signals due to pickup. attach probe with end cap and ground clip removed to circuit shown below wh ich is attached to end of output cable. the 5125ba probe adapter is affi xed probe ground probe tip figure 22 ? oscillo scope probe prepa red for rip p le measur ement (end ca p an d grou nd le a d remove d). r ca ble (0. 15 ?) d a d b r ba ttery (0. 44 ?) c a 10, 000 f r lo ad (13 ?) figure 23 ? equivalent battery model circuit. page 24 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 12.5.2 measurement results figure 24 ? output rip p le , 115 vac, full load. 20 s, 50 mv / div. figure 25 ? output rip p le , 230 vac, full load. 20 s, 50 mv / div. page 25 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 13 conducted emi conducted emissions tests were complet ed at 115 vac and 230 vac at full load, 5.5 v / 400 ma. measurements were comp leted with artificial hand c o nnection and floating dc output load resistor. an output dc cable was included. composite en55022b / cispr22b conducted limits are shown. 13.1 115 vac i nput, full load l i n e n e u t r a l artific i al hand connec ted to output ret u rn artific i al hand connec ted to output ret u rn output floati n g output floati n g page 26 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 13.2 230 vac i nput, full load l i n e n e u t r a l artific i al hand connec ted to output ret u rn artific i al hand connec ted to output ret u rn output floati n g output floati n g page 27 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 14 appendix a ? design modificatio n required t o remove y cap acitor in some applications where extremely low leakage current is required, it may be necessary to remove the y c apacitor (c y1) that bridges t he primary-to-secondar y isolation barrier. in order to achieve this while s t ill meet ing conducted and radiated emi requires re- optimization of the transformer. as with all no y c apacitor transformer designs, th e mechanical arrangement and relative spac ing of the windings has a large impact on the emi performance of the supply. therefor e ensure that transformers are wound consistently to ensure repeatable emi performance. 14.1 no y capacitor transformer specification 14.1.1 electrical diagram 9 t 25 a w g t.i . w. 17 t 2 x 3 2 aw g f l oa t i ng 5 n/c 9 8 7 t 3 x 2 8 aw g n/c 4 11 4 t 36 awg 3 5 win d in g #1 (ca n ce llation ) win d in g #3 (shie l d) win d in g #2 (p rimary ) win d in g #4 (se c on da ry) d e not es mec h anic a l s t art of r e v e rs e w o und winding whe r e el e c t r i c al ph as ing a nd mechan i c al s t art are not t he same 14.1.2 electrical specifications electrical str e ngth 60hz 1min ute, from pins 3-5 to pins 6 - 10 3000 vac primar y indu ctan ce pins 3-5, all other win d ing s open, mea s u r ed at 200 khz, 0.4 vrms 916 h, -/+12 % reso nan t fr equen c y pins 3-5, all other win d ing s open 900 khz (min .) primar y leakage induc ta nce pins 3-5, with pins 8-9 sho r ted, mea s ured at 200 khz, 0.4 vrms 75 h (max .) page 28 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 14.1.3 winding instructions wd 1 can c ell a tion windi ng primary pin si de of the bob bin orie nted to left-hand si de. add 1 layer of item [7] to the second ary si de. start at pin 5. wind 17 bifilar turn s of item [3] from right to left. wind with ti ght tension across entire bobbi n evenly. cut the end s of the bifilar and leave float ing. insulatio n 4 layers of tape [8] for insu lation. wd#2 primary wi ndi ng apply 1 layer of item [7] to the se co nda ry 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 s e condary s i de. wind another 40 turns from right to left. add 1 layer o f item [8] and 1 layer of item [7] to the seco nda ry sid e . wind 34 turns in third layer from left to right. wind with tight tensi on a c ro ss entire bo bbin evenly. finish at pin 5. insulatio n 2 layers of tape [8] for insu lation. wd # 3 shield winding start at pin 8 temporarily, wind 7 trifila r turns of item [5]. wind from right to left with tig h t tension. wi nd uniformly, in a singl e layer acro ss enti r e width of bob b i n. finish on pin 4. cut the lead of the starting en d an d ensure that th e void area a r ound the start i ng end i s ent irely cove red with the cut end. t ape do wn in place. insulatio n 2 layers of tape [8] for insu lation. wd # 4 se c o nd ar y windi ng reverse o r ie ntation of bob bin su ch that se con dary pi n side i s to the left- hand side. start at pin 8, wind 9 turns of item [6] from right to left. wind uniformly, in a singl e layer acro ss entire bobbin eve n l y . finish on pin 9. outer in sulati on 3 layers of tape [8] for insu lation. cor e a s semb ly a sse mble a n d se cur e co re halv e s u s ing it em [ 9 ] . core groun di ng solder 1 e nd of item [10] to pin 5. wrap 2 turns aro u n d entire tra n sf orme r makin g su re t hat wire i s in conta c t with core s. termi n ate end to pin 5. varni s h dip varnish, item [11] 14.1.4 materials i t e m d e s c r i p t i o n [1] core: pc40e e16-z, tdk o r equivale nt gapp ed for a l of 192 nh/t 2 [2] bobbin: ee16 hori zontal 1 0 pin [3] magnet wire: #32 awg [4] magnet wire: #36 awg [5] magnet wire: #28 awg [6] triple in sulat ed wire: #25 awg. [7] tape: 3m # 4 4 polyester web. 1.5 mm wide [8] tape: 3m 12 98 polyeste r film, 2.0 mils thick, 8.0 m m wide [9] tape: 3m 12 98 polyeste r film, 2.0 mils thick, 3.0 m m wide [10 ] solid wire: #28 awg [11 ] varnis h page 29 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 14.1.5 transformer build diagram 1. 5 mm 1. 5 mm 5 5 3 4 9 8 n.c. (floa t ing ) n.c. 4 lay e r s of tape 3 lay e rs of tape secon d ary sh iel d pr im ary cancellatio n tape margin d e not es me cha n ica l s t art o f wi nding where m e ch anic a l s t art and e l ec t r ica l ph ase are di f f e ren t d e not es me cha n ica l s t art a n d elec t r ic al ph ase of win d ing wh ere t hey are t he s a me page 30 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 14.2 em i results both conducted and radiated emi results wit h the revis ed transformer and cy1 removed showed excellent margin to respective st andards. tests were performed on both line a n d neutral (conducted) with the output return connec ted to the artificial h and input of the lisn (line impedance stabilization network). the red trace represents emi measured with a quasi peak detector and the blue an av erage 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 cap a cit o r co ndu cted emi results (115 vac). page 31 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 figure 27 ? no y cap a cit o r co ndu cted emi (230 vac). page 32 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter 15 revision history date author revision description & chang es 0 1 - m a r - 0 4 a o 0 . 1 first d r a f t 01-apr-04 0.2 transformer and layout change 05-apr-04 pv 0.3 applied cor r ect template, updated circuit description 08-apr-04 pv 0.4 reins e rted figure 4 (didn?t printout) 2 8 - a p r - 0 4 a o 0 . 5 updated bom, spreadsheet, schematic and transforme r 02-may-04 pv 0.6 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 20-may-04 ao 0.7 added output characteristic spec 27-may-04 pv 0.8 updated pcb layout, charts corrected 1 6 - j u n e - 0 4 p v 0 . 8 1 r10 par t number corrected figure 2 updated (q1 shown as npn not pnp) 24-june-04 pv 0.9 reins e rted final spreadsheet 2 5 - o c t - 0 4 p v 1 . 0 appendix a added for no y cap solution page 33 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 notes po w e r integrati ons page 34 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m 25-oct-2004 ep-73 5.7 v, 400 ma charger / adapter notes page 35 of 36 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m ep-73 5.7 v, 400 ma charger / adapter 25-oct-2004 f o r the l a t e s t upd a t es , v i s i t o u r w e bs i t e: w ww. p o we r i n t .c o m p o w e r i n t e g r a t i o ns m a y m a k e c h a n ge s t o i t s p r od uc t s a t a n y t i m e . p o w e r i n t e g r a t i o n s ha s n o l i a b i l i t y a r i s i n g f r om y o u r u s e o f an y i n f o r m a t i o n , de vi c e o r c i r c u i t de sc r i b e d he r e i n no r d o e s i t c o n v e y a n y l i c e n se u n d e r i t s p a te n t r i g h t s or t h e r i g h t s o f othe r s . po w e r i n teg r a ti o n s m a k e s n o w a r r a n ti es h e r e i n a n d s p ec i f i c a l l y d i s c la i m s a l l w a r r a n t i e s i n c l u d i n g , w i t h ou t l i m i t a t i o n , t h e i m p l i e d w a r r ant i e s of m e r c h ant ab i l it y , f i t n e s s f o r a p a r t ic ula r p u r p os e , an d n o n - i n f r i n g e m e n t of t h ir d p a r t y r i g h t s . p a t e nt i n f o r m at i o n t h e pr o d u c t s a n d a p pl i c a t i o n s i l l u s t r a t e d he r e i n ( i nc l u d i ng c i r c u i t s e x t e r n a l t o t h e pr o d u c t s a n d t r a n s f or m e r c o n s t r u c t i o n ) m a y be c o v e r e d by on e or mo r e u . s . a n d f o r e i g n p a te n t s o r po t e nt ia l l y b y p e nd i n g u . s . a n d f o r e ig n pa t e n t a p pli c a t i on s a ssi g n e d t o p o w e r i nte g r a t i o ns. a c o mp l e t e li st o f p o w e r i nte g r a t i o n s ? p a te n t s ma y be f o un d a t w w w . p ow e r i n t. c o m . th e p i l o g o , t o psw it c h , t i ny s w i t ch , l i nks w i t c h , dp a - s w i t c h an d e cos m a r t a r e r e g i s t e r ed t r ad e m a r k s o f po w e r i n t e g r a t i o n s . p i e xper t an d p i f a c ts a r e t r a d e m a r k s of p o w e r i n t e gr a t i o ns . ? c opy r i g h t 2 0 0 4 , p o w e r i n t e g r a t i ons . pow e r i n t e gr at i ons w o r l d w i d e sa l e s s u ppor t lo cat i ons w o rl d h e a d q u a r t e rs 5245 h e llye r a v e n u e , s a n jo se , c a 9 5 1 3 8 , u s a m a i n : + 1 - 4 0 8 - 414 - 9 2 00 cu s t o m er s e r v i ce: p h o n e : + 1 - 4 0 8 - 414 - 9 6 65 f a x : + 1 - 4 0 8 - 414 - 9 7 65 e- m a il : u s a s a l es @p o w er i n t . co m g e rman y r u eck e r ts t r as s e 3 , d - 8 0 3 3 6, m u nic h , g e r m a ny p h on e : + 4 9 - 89 5 - 5 2 7 - 39 1 0 f a x : + 4 9 - 8 9 5 - 5 2 7- 3 9 20 e - m a i l : e u ro sa l e s@p o w e ri n t . c o m ja p a n k e ih in - t a t em o n o 1 s t b l d g . 12- 20 s h i n - y o k o h a m a , 2- c h o m e , ko h o k u - k u , yo ko h a m a - s h i , k a na g a w a 22 2 - 0 0 3 3 , j a pa n p h o n e : + 8 1 - 4 5 - 471 - 1 0 21 f a x : + 8 1 - 4 5 - 471 - 3 7 17 e- m a il : j a pa ns a l es @ p o w e r int. c o m t a i w an 5 f - 1 , no . 31 6 , ne i hu r d . , se c . 1 n e i h u d i s t . ta i p e i , ta i w a n 1 1 4 , r . o . c . p h o n e : + 8 8 6 - 2 - 265 9- 4 570 f a x : + 8 8 6 - 2 - 265 9- 4 550 e- m a il : t a i w a n sa l e s@p o w e ri n t . c o m c h in a ( s ha n gha i ) r m 807 - 8 08 a , p a c h e e r , co m m e r c ial ce n t r e , 555 n a nji n g w e s t r o a d , s h a n gha i , 2 0 00 4 1 , c h i n a p h o n e : + 8 6 - 2 1 - 621 5 - 5 548 f a x : + 8 6 - 2 1 - 621 5 - 2 468 e- m a il : c h in as al es @ p o w e r i n t. c o m i ndi a ( t e c h n i c al su p p or t ) i nno va te c h 26 1/ a, g r o u n d f l o o r 7 t h m a in , 17 th cr os s , sa d a s h i v a n a g a r b a ngal o re 5 600 80 p h on e : + 9 1 - 80 - 5 1 1 3 - 80 2 0 f a x : + 9 1 - 8 0 - 5 1 1 3- 8 0 23 e- m a i l : i n d i a s a l e s @ p o w erin t. co m kor e a rm 6 0 2 , 6 f l ko rea ci ty ai r t e r m i n a l b / d , 159 - 6 , s a m s u n g- d o ng , k a ng na m - g u , s e o u l, k o r ea p h o n e : + 8 2 - 2 - 2 016 - 6 6 10 f a x : + 8 2 - 2 - 2 016 - 6 6 30 e- m a il : ko r e a s a l e s @ p o w er i n t . co m u k ( e ur o p e & a f r i ca h e adq u a r t e r s ) 1 s t fl o o r , st . j a m e s ? s h o u s e ea s t s t r e e t fa r n ha m , s u r r e y g u 9 7t j un i t e d k i ngd o m p h o n e : + 44 ( 0 ) 125 2- 7 3 0 - 1 4 0 f a x : + 44 ( 0 ) 125 2- 7 2 7 - 6 8 9 e - m a i l : e u ro sa l e s@p o w e r i n t . c o m c h i n a ( s he n z he n ) r o o m 2 206 - 2 207 , b l o c k a , e l e c tr o n ic s s c ie n c e & t e c h n o l o g y bl d g . , 2070 s h e n na n z h o n g r o a d , s h en z h en , g u an g d o n g , ch i n a , 5 1 8 0 3 1 p h o n e : + 8 6 - 7 5 5 - 83 7 9 - 324 3 f a x : + 8 6 - 7 5 5 - 83 7 9 - 582 8 e- m a il : ch i n a s a l e s @ p o w er i n t . c o m it a l y v i a v i t t o r io v e n e to 1 2 , b r e sso m i la n o , 20 0 9 1, ita l y p h o n e : + 3 9 - 02 8 - 928 - 6 0 01 f a x : + 3 9 - 02 8 - 928 - 6 0 09 e - m a i l : e u ro sa l e s@p o w e ri n t . c o m si ng ap o r e 51 n e w t o n r o a d , #15 - 0 8 / 10 g o ld hill p l a z a , s i nga p o r e , 3 0 8 9 00 p h o n e : + 6 5 - 6 3 58 - 2 1 60 f a x : + 6 5 - 6 3 58 - 2 0 15 e- m a il : s i n gap o r e s ale s @ p owe r in t. com a p p l i c at i o ns h o t l i ne w o r l d w i de + 1 -4 0 8 - 4 1 4 - 9 6 6 0 a p p l i c at i o ns f ax w o r l d w i de + 1 -4 0 8 - 4 1 4 - 9 7 6 0 page 36 of 36 tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m po w e r integrati ons |
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