Design Example Report

Transcription

1 Design Example Report Title Specification Application Author Document Number 2.4W Power Supply using LNK520P Input: VAC Output: 5.0 V / 480 ma Cell Phone Charger Applications Department DER-38 Date April 28, 2004 Revision 1.0 Summary and Features Low Cost, Low Component Count Design High Efficiency (> 70 %) at Full Load Accurate Output Voltage Regulation (using Opto-Coupler Feedback) Low Standby Consumption (< 250mW) Meets EMI Without Y-capacitor for Low Leakage Small Low Cost EE13 Transformer Universal 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. A complete list of patents may be found at Hellyer Avenue, San Jose, CA USA.

2 Table Of Contents 1 Introduction Power Supply Specification Schematic Circuit Description Input EMI Filtering LinkSwitch Primary Output Rectification Output Feedback No Load Consumption PCB Layout Bill Of Materials...8 Transformer Specification b Electrical Diagram Electrical Specifications Materials Transformer Build Diagram Transformer Construction Transformer Spreadsheets Performance Efficiency No-Load Input Power Regulation Measurement Data Waveforms Drain Voltage and Current, Normal Operation Load Transient Response (75% to 100% Load Step) Output Ripple Measurements Ripple Measurement Technique Measurement Results Conducted EMI Revision History...22 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. Page 2 of 23

3 1 Introduction This document is an engineering report describing a prototype cell phone power supply utilizing a LNK520P. This power supply is intended as a general purpose evaluation platform for this LinkSwitch device. 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. Page 3 of 23

4 2 Power Supply Specification Description Symbol Min Typ Max Units Comment Input Voltage V IN VAC 2 Wire no P.E. Frequency f LINE 47 50/60 64 Hz No-load Input Power (230 VAC) 0.3 W Output Output Voltage 1 V OUT V ± 5% Output Ripple Voltage 1 V RIPPLE1 mv 20 MHz bandwidth Output Current 1 I OUT ma ± 25% Total Output Power Continuous Output Power P OUT 2.4 W Peak Output Power P OUT_PEAK W Efficiency η 70 % Measured at P OUT (43 W), 25 o C Environmental Conducted EMI Safety Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Surge 2 kv Surge 2 kv Ambient Temperature T AMB 0 50 o C 1.2/50 µs surge, IEC , Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω 100 khz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level Regualtion Specification Voltage (V) MIN MAX Load (ma) Page 4 of 23

5 3 Schematic Figure 2 Schematic. Page 5 of 23

6 4 Circuit Description 4.1 Input EMI Filtering Resistor RF1 acts as a fuse for the entire power supply and also limits different surge. Diodes D1, D3, D5, D7 and Capacitors C5, C6 rectify and filter the input waveform to produce a high voltage DC-bus. Inductors L1 and L3 work in conjunction with C5 and C6 to filter and attenuate conducted EMI. 4.2 LinkSwitch Primary Diode D10 and capacitor C12 rectify and filter the bias voltage. The diode is in a low-side configuration to allow the bias-winding to act as a primary cancellation winding. Components C3, R3, R4, and D4 form an RCD clamp to capture the leakage spike at Drain turn-off. A slow diode (D4) is used to allow recovery of some of this leakage inductance energy. The remainder is captured in C3 and dissipated in R Output Rectification Output diode D2 and capacitor C7 rectify and filter the output voltage. 4.4 Output Feedback Resistor R9 is used to bias the Zener reference (VR1), adjusting this resistor will adjust the output voltage. Resistor R10 is used to control the opto-coupler current, and depending on the value can also change the output voltage set-point. The opto-coupler U2 transfers the feedback signal across the isolation barrier to the primary side of the supply. Resistor R6 set s the maximum power point before the supply transitions into constant current mode. 4.5 No Load Consumption No-load consumption is affected by the choice of bias winding components. Use of a slow diode (1N4005GP) makes no-load consumption worse (by about 50mW at low-line), but gives the best CC regulation. Use of a fast diode D6 (such as 1N914) on the bias winding dramatically improves no-load consumption. However use of a fast diode also makes the constant-current (CC) regulation significantly non-linear. The absence of an R- C snubber on the bias-winding, slightly improves the no-load consumption (10mW at lowline). Also the choice of Zener current setting resistor R9 affects the no-load consumption (again by approx 10mW at low-line). The value of resistor R7 has no effect on the no-load consumption. The set-point of the output voltage has a significant effect on the no-load consumption (high output voltage, higher no-load consumption) e.g. going from Vout = 5.44 V to Vout = 6.5 V, the no-load consumption increased by 50mW. Page 6 of 23

7 5 PCB Layout Figure 3 Printed Circuit Layout. Page 7 of 23

8 6 Bill Of Materials Item Quantity Part Reference Description Part Number Mfg Part Number CAP 470pF 100V CERM CHIP X7R ECU- 1 1 C SMD V1H471KBN 2 2 C5 C6 Cap,Al Elect,4.7uF,400V,8mmX11.5mm,Sam Young SHD400WV 4.7uF 3 1 C7 Cap,Al Elect,330uF,16V,8mmX11.5mm,KZE Series,NIPPON CHEMI-CON KZE16VB331MH 11LL 4 1 C10 CAP 0.22uF 25V CERM CHIP X7R 0805 SMD ECJ- 2YB1E224K 5 1 C12 Cap,Cer, 1.0 uf, 50V, 10% ECU- S1H105KBB 6 D1 D3 D5 5 D7 D10 Rectifier GPP 600V 1A DO N4005-T 7 1 D2 Diode Schottky 60V 1.1A DO DQ D4 Rectifier GPP 1000V 1A DO-41 TMP-59 1N4007GDICT 10 2 J1 J2 Terminal,1Pin,22AWG J3 J4 Terminal,1Pin,18AWG SBCP_47HY L1 CHOKE,1mH,SBCP_47HY102B,TOKIN B 12 2 L3 CHOKE,FERRITE BEAD ERJ R3 Res,150K 1/16W 5% 0603 SMD GEYJ154V 14 1 R4 Res,300 1/10W 5% 0805 SMD ERJ- 6GEYJ301V 15 1 R6 Res,7.50K 1/16W 1% 0603 SMD ERJ-3EKF7501V 16 1 R7 Res,15 1/16W 5% 0603 SMD ERJ- 3GEYJ150V 17 1 R9 Res,680 1/16W 5% 0603 SMD ERJ- 3GEYJ681V 18 1 R10 Res,120 1/16W 5% 0603 SMD ERJ- 3GEYJ121V 19 1 RF1 Res, 8.2,1W, 5%, Metal Film RSF200JB- 0R T1 BEE16_H_LOPROFILE_10P U1 IC,LNK 520P,CV or CV/CC SWITCHER,PLAS,DIP-8B TMP-111 LNK520P 22 1 U2 IC,PC817D,PHOTOCOUPLER TRAN OUT 4-DIP PC817D 23 1 VR1 DIODE ZENER 4.7V 500MW MINIMELF ZMM5230B-7 Page 8 of 23

9 Transformer Specification b 6.1 Electrical Diagram 2 1 W1: 39T 1 x 34 AWG W2: 114T 1 x 35 AWG W4: 12T 1 x 26 TIW 8 3 FL1 W3: 13T 2 x 31 AWG Figure 4 Transformer Electrical Diagram 6.2 Electrical Specifications Electrical Strength 1 second, 60 Hz, from Pins 2-1,3-4 to Pins VAC Primary Inductance Pins 4-3, all other windings open, measured at 2390 µh, khz, 0.4 VRMS 0/+20% Resonant Frequency Pins 4-3, all other windings open 300 khz (Min.) Primary Leakage Inductance Pins 4-3 with Pins 7-8 shorted, measured at 100 khz, 0.4 VRMS 100 µh (Max.) 6.3 Materials Item Description [1] Core: TDK PC40 EE13, AL = 185 nh/t 2 [2] Bobbin: EE13 Horizontal [3a] Magnet Wire: 34 AWG [3b] Magnet Wire: 35 AWG [3c] Magnet Wire: 31 AWG [3d] Triple Insulated Wire: 26 AWG (TIW) [4a] Tape [6] Varnish Page 9 of 23

10 6.4 Transformer Build Diagram 3 FL1 3 8 W4 7 Tape W3 Shield Floating Tape W2 Primary Tape W1 Cancellation Figure 5 Transformer Build Diagram. 6.5 Transformer Construction Shield 1 Start at Pin 1. Wind 39 turns of item [3a] in approximately 1 layer. Finish at Pin 2. Basic Insulation Use two layers of item [6] for basic insulation. Start at Pin 4. Wind 114 turns of item [3b] in approximately 3 layers. After Primary 1 st layer insert one layer of tape. Complete 2nd layer insert one layer of tape. Complete 3 rd layer. Finish at Pin 3. Basic Insulation Use two layers of item [6] for basic insulation. Temporary start at Pin 2. Wind 13 turns of bifilar item [3c]. Spread turns Shield 2 evenly across bobbin. Finish at Pin 3. (Disconnect from pin 2 and leave floating (FL1) in the stack.) Basic Insulation Use one layer of item [7] for basic insulation. Secondary Winding Temporary start at pin 2. Wind 12 turns of item [3d] in 1 layer. Finish on Pin 8. Move connection from pin 2 to pin 7. Outer Wrap Wrap windings with 3 layers of tape [item [4a]. Final Assembly Assemble and secure core halves. Varnish dip (item [6]). Page 10 of 23

11 7 Transformer Spreadsheets LinkSwitch (LNK52X) ; Rev.1.7; Copyright 2004 INPUT INFO OUTPUT UNIT ENTER APPLICATION VARIABLES LinkSwitch (LNK52X) Rev.1.7; Copyright Power Integrations 2004 DI A VACMIN 85 Volts Minimum AC Input Voltage VACMAX 265 Volts Maximum AC Input Voltage fl 50 Hertz AC Mains Frequency VO 5 Volts Output Voltage IO 0.48 Amps Continuous Nominal Output current VBIAS 20 Bias voltage (recommended default 20V, minimum 16V) tc 3 msec Bridge Rectifier Conduction Time Estimate CIN 9.4 ufarads Input Filter Capacitor ESTIMATED LOSSES PCORE mw Estimated Core Losses at peak Flux Density (BP) RCLAMP 200 Kohm Primary clamp resistor (recommended default clamp resistor, RCLAMP) ESR 0.15 Ohms Output Capacitor ESR RSEC 0.2 Ohms Estimated Resistance of transformer secondary winding. DC INPUT VOLTAGE PARAMETERS VMIN Volts Minimum DC Input Voltage VMAX Volts Maximum DC Input Voltage ENTER OUTPUT CABLE PARAMETERS RCABLE 0.3 Ohms Resistance of total length of cable from power supply terminals to load and back. VCABLE Volts Drop along cable connecting power supply to load ENTER LinkSwitch & OUTPUT DIODE VARIABLES LinkSwitch LNK520 Universal 115 Doubled/230 Power I^2 f 2710 A^2 Hz I^2 f (typical) co-efficient for LinkSwitch VOR Volts Reflected Output Voltage (40<VOR<80 recommended) VLEAK 2 Volts Error in Feedback voltage as a result of leakage inductance in primary circuit. VD Volts Output Winding Diode Forward Voltage Drop (0.5~0.7V for schottky and 0.7~1.0V for PN diode) VR 60 Volts Rated Peak Rep Reverse Voltage of secondary diode ID 1.1 Amps Rated Average Forward current for secondary diode DISCONTINUOUS MODE CHECK KDP Ensure KDP > 1.15 for discontinuous mode operation. TON us Linkswitch conduction time TDON us Secondary Diode conduction time VOLTAGE STRESS ON LinkSWITCH AND OUTPUT DIODE VDRAIN Volts Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) PIVS Volts Output Rectifier Maximum Reverse Voltage CURRENT WAVEFORM SHAPE PARAMETERS DMAX Maximum Operating Duty Cycle IAVG Amps Average Primary Current IRMS Amps Primary RMS Current Page 11 of 23

12 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE13 Core PC40EE13-Z Bobbin BE-13 AE cm^2 Core Effective Cross Sectional Area LE 3.02 cm Core Effective Path Length AL 1130 nh/t^2 Ungapped Core Effective Inductance VE 517 mm^3 Effective Core Volume BW 7.4 mm Bobbin Physical Winding Width KCORE kw/m^3 Core losses per unit volume T(n) Estimated transformer efficiency. T(n)=(PSCU+PCORE/2)/POEFF. Re-iterate with n = M 0 mm Safety Margin Width NS 12 Number of Secondary Turns TRANSFORMER PRIMARY DESIGN PARAMETERS dlp Constant to account for reduction of inductance at higher flux densities. (0.999<dLP<1.05) LP uhenries Primary Inductance L 3 3 Number of Primary Layers LBIAS 1 1 Number of Bias winding Layers NP Primary Winding Number of Turns NB ALG nh/t^2 Gapped Core Effective Inductance BP Gauss Peak Flux Density (BP<3700) LG mm Core Gap Length for primary inductance OD mm Maximum Primary Wire Diameter including insulation to give specified number of layers. DIA mm Bare conductor diameter AWG 35 AWG Primary Wire Gauge (Rounded to next smaller standard AWG value) CMA Cmils/Amp Primary Winding Current Capacity (200 < CMA < 500) AWG_BIAS 32 AWG TRANSFORMER SECONDARY DESIGN PARAMETERS ISP Amps Peak Secondary Current ISRMS Amps Secondary RMS Current IRIPPLE Amps Output Capacitor RMS Ripple Current AWGS 30 AWG Secondary Wire Gauge (Rounded up to next larger standard AWG value) DIAS mm Secondary Minimum Bare Conductor Diameter ODS mm Secondary Maximum Insulated Wire Outside Diameter INSS mm Maximum Secondary Insulation Wall Thickness VSEC Volts Voltage Drop across secondary winding FEEDBACK CIRCUIT COMPONENTS RFB k-ohms Feedback resistor PRFB mw Losses in the Feedback resistor ESTIMATED LOSSES IN POWER SUPPLY AND EFFICIENCY, LOW LINE PCABLE mw Power loss in Output Cable PSCU mw Transformer Secondary Copper Losses PDIODE mw Output Diode conduction loss PCAP mw PBIAS 50.6 mw Power Loss in Feedback circuit PCONDUCTION mw Conduction Losses in LinkSwitch calculated at 100C PCLAMP mw Primary clamp losses PCORE mw Core Losses at peak Flux Density PBRIDGE mw Primary bridge rectifier losses EFFICIENCY ESTIMATE % Estimated Power Supply Efficiency ADDITIONAL OUTPUT VX Volts Auxiliary Output Voltage VDX Volts Auxiliary Diode Forward Voltage Drop NX 0 Auxiliary Number of Turns PIVX 0 Volts Auxiliary Rectifier Maximum Peak Inverse Voltage Page 12 of 23

13 8 Performance 8.1 Efficiency Efficiency vs Load a 80.00% Efficiency (%) 70.00% 60.00% 85VAC 115VAC 230VAC 265VAC 50.00% Load (ma) Figure 6- Efficiency vs. Input Voltage, Room Temperature, 60 Hz. 8.2 No-Load Input Power No Load Consumption a Pin (W) No Load Vin (VAC) Figure 7 Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. Page 13 of 23

14 8.3 Regulation Regulation a 7 6 Voltage (V) MIN MAX 85 VAC 115 VAC 230 VAC 265 VAC Load (ma) Figure 8 Line and Load Regulation, Room Temperature. Page 14 of 23

15 8.4 Measurement Data Vin Pin Vout Iout Pout Eff Page 15 of 23

16 9 Waveforms 9.1 Drain Voltage and Current, Normal Operation Figure 9-85 VAC, Full Load (5.13 V/ 484 ma). Upper: V DRAIN, 200 V / div, Lower: I DRAIN, 0.1 A, 5 µs / div Figure VAC, Full Load (5.19 V/ 490 ma) Upper: V DRAIN, 200 V / div, Lower: I DRAIN, 0.1 A, 5 µs / div Page 16 of 23

17 9.2 Load Transient Response (75% to 100% Load Step) In the figures shown below, no signal averaging was used. The oscilloscope was triggered using the load current step as a trigger source. Figure 11 Transient Response, 115 VAC, % Load Step. Top: Output Voltage, 200 mv/div. Bottom: Load Current 200 ma, 2ms / div. Figure 12 Transient Response, 230 VAC, % Load Step. Top: Output Voltage, 200 mv/div. Bottom: Load Current 200 ma, 2ms / div. Page 17 of 23

18 9.3 Output Ripple Measurements 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 µf/50 V ceramic type and one (1) 1.0 µf/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 13 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 14 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added) Page 18 of 23

19 9.3.2 Measurement Results Figure 15 - Ripple, 85 VAC, Full Load. 2 ms, 50 mv / div Figure 16-5 V Ripple, 115 VAC, Full Load. 2 ms, 50 mv / div Figure 17 - Ripple, 230 VAC, Full Load. 2 ms, 50 mv /div Page 19 of 23

20 10 Conducted EMI Figure 26 - Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits Ungrounded Secondary. Figure 26 - Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits Grounded Secondary Page 20 of 23

21 Figure 27 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits - Ungrounded Secondary Figure 27 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits - Ungrounded Secondary Page 21 of 23

22 11 Revision History Date Author Revision Description & changes Reviewed April 28, 2004 RM 1.0 Initial release VC / AM Page 22 of 23

23 For the latest updates, visit our Web site: may make changes to its products at any time. 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. A complete list of patents may be found at. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of. Copyright 2004,. WORLD HEADQUARTERS 5245 Hellyer Avenue, San Jose, CA 95138, USA Main: Customer Service: Phone: Fax: usasales@powerint.com CHINA (SHENZHEN) International Holdings, Inc. Rm# 1705, Bao Hua Bldg Hua Qiang Bei Lu, Shenzhen, Guangdong, , China Phone: Fax: chinasales@powerint.com ITALY s.r.l. Via Vittorio Veneto 12, Bresso, Milano, 20091, Italy Phone: Fax: eurosales@powerint.com SINGAPORE (ASIA PACIFIC HEADQUARTERS), Singapore 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, Phone: Fax: singaporesales@powerint.com AMERICAS, Inc South Lee Street, Suite G, Buford, GA 30518, USA Phone: Fax: usasales@powerint.com GERMANY, GmbH Rueckertstrasse 3, D-80336, Munich, Germany Phone: Fax: eurosales@powerint.com JAPAN, K.K. Keihin-Tatemono 1st Bldg Shin-Yokohama, 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa , Japan Phone: Fax: japansales@powerint.com TAIWAN International Holdings, Inc. 17F-3, No. 510, Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. Phone: Fax: taiwansales@powerint.com CHINA (SHANGHAI) International Holdings, Inc. Rm 807, Pacheer, Commercial Centre, 555 Nanjing West Road, Shanghai, , China Phone: Fax: chinasales@powerint.com INDIA (TECHNICAL SUPPORT) Innovatech 261/A, Ground Floor 7th Main, 17th Cross, Sadashivanagar Bangalore, India, Phone: Fax: indiasales@powerint.com KOREA International Holdings, Inc. 8th Floor, DongSung Bldg Yoido-dong, Youngdeungpo-gu, Seoul, , Korea Phone: Fax: koreasales@powerint.com UK (EUROPE & AFRICA HEADQUARTERS) 1st Floor, St. James s House East Street Farnham, Surrey GU9 7TJ United Kingdom Phone: Fax: eurosales@powerint.com APPLICATIONS HOTLINE World Wide ER or EPR template Rev 3.5 Single sided APPLICATIONS FAX World Wide Page 23 of 23