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Title
Engineering Prototype Report for EP-54 - 2.75 W Charger/Adapter Using LNK520P (LinkSwitch)
Specification 85-265 VAC Input, 5.5 V, 500 mA, 2.75 W Output Application Author Document Number Date Revision
Low Cost Charger / Adapter Power Integrations Applications Department EPR-54 07-May-2004 1.1
Summary and Features
* * Low cost, low component count battery charger/adapter - replaces linear transformer based solutions Optimized switching characteristics and low-side configuration of LNK520 minimizes EMI - Achieves greater than 10 dBV margin to composite conducted limits - No Y1 safety capacitor required for EMI compliance - Ultra-low earth leakage current, <5 A Small low cost EE16 transformer - Provision for EE13 transformer for smaller size Approximate constant voltage, constant current (CV/CC) primary sensed output characteristic Efficiency greater than 65% across all line/load conditions
* * *
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.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
Table Of Contents
1 2 3 4 Introduction.................................................................................................................4 Power Supply Specification ........................................................................................5 Schematic...................................................................................................................6 Circuit Description ......................................................................................................7 4.1 Input EMI Filtering ...............................................................................................7 4.2 LinkSwitch Primary and Output Feedback...........................................................7 4.3 Output Rectification .............................................................................................9 5 PCB Layout ................................................................................................................9 6 Bill Of Materials ........................................................................................................10 7 Transformer Specification.........................................................................................11 7.1 Electrical Diagram .............................................................................................11 7.2 Electrical Specifications.....................................................................................11 7.3 Materials............................................................................................................12 7.4 Transformer Build Diagram ...............................................................................13 7.5 Transformer Construction..................................................................................15 7.6 Transformer Bobbing Drawing...........................................................................16 8 Performance Data ....................................................................................................17 8.1 Efficiency ...........................................................................................................17 8.2 No-load Input Power..........................................................................................18 8.3 Regulation .........................................................................................................19 8.3.1 Line and Load ............................................................................................19 8.4 Thermal Performance........................................................................................20 9 Waveforms ...............................................................................................................22 9.1 Drain Voltage and Current, Normal Operation...................................................22 9.2 Output Voltage Start-up Profile (Battery Load) ..................................................22 9.3 Drain Voltage and Current Start-up Profile ........................................................23 9.4 Load Transient Response (75% to 100% Load Step) .......................................24 9.5 Output Ripple Measurements............................................................................25 9.5.1 Ripple Measurement Technique ................................................................25 9.5.2 Ripple Measurement Results .....................................................................26 10 Conducted EMI .....................................................................................................27 11 Appendix A: EE16 Simple Construction................................................................29 11.1 Introduction........................................................................................................29 11.2 Schematic..........................................................................................................29 11.3 Bill of Materials ..................................................................................................29 11.4 Transformer Specification..................................................................................31 11.4.1 Transformer Winding..................................................................................31 11.4.2 Electrical Specifications..............................................................................31 11.4.3 Transformer Build Diagram ........................................................................32 11.5 Performance Data .............................................................................................32 11.5.1 Efficiency....................................................................................................33 11.5.2 Line and Load Regulation ..........................................................................34 11.6 Conducted EMI..................................................................................................34 12 Revision History ................................................................................................36
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
1 Introduction
This document is an engineering report describing a 5.5 V, 500 mA charger/adapter power supply. The power supply utilizes the LinkSwitch LNK520 device, optimized for bias winding feedback. The LinkSwitch integrates a 700 V MOSFET, PWM controller, start-up, thermal shut-down, 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 range and high energy efficiency. Compared to the LNK500, the optimized switching characteristics of the LNK520 and the low-side configuration provides improved EMI performance and less variation in EMI performance from design to design. 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.
An alternate design utilizing simplified EE16 transformer construction is presented. See Appendix A for schematic, construction details and performance curves.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power Output Output Voltage Output Ripple (resistive load) Output Ripple (battery load) Output Current Output Envelope Total Output Power Continuous Output Power Efficiency Environmental Conducted EMI Safety Surge Surge Ambient Temperature TAMB
Meets CISPR22B / EN55022B Designed to meet IEC950/UL1950 No Y1 Safety Capacitor Class II 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 In provided enclosure, free convection, sea level
Symbol VIN fLINE
Min 85 47
Typ
Max 265 64 0.3 6
Units VAC Hz W V mV mV mA
Comment
2 Wire - no protective ground. Measured at 230 VAC + 10% 20% (at peak power point) Resistive load (peak power) Battery load (peak power) 25% (at peak power point ) See figure 3
50/60
VOUT VRIPPLE(R) VRIPPLE(B) IOUT
5.0
375
5.5 300 150 500
625
POUT
2.06 65
2.75
3.43
W %
Measured at POUT (2.75 W), 25 C
o
2 2 0 40
kV kV
o
C
Table 1 - EP54 Power Supply Specification.
Figure 2- EP54 Output Characteristic Specification.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
Note: EP-54 is designed for a battery load. If a resistive or electronic load is used the supply may fail to start up at full load. This is normal. To ensure startup into a resistive load, increase the value of C5 to 1 F (see circuit description for more information).
3 Schematic
Figure 3 - Schematic.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
4 Circuit Description
The circuit schematic shown in Figure 3 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 2.75 W with nominal peak power point voltage of 5.5 V and a current of 500 mA. The overall operating envelope is shown in Figure 10. The unit provides a CC operating range of 25% over a case internal temperature range of 25 C to 65 C, and a transformer primary inductance tolerance of 10%. Appendix A details the performance of a simplified EE16 transformer without using foil in the construction. This may be a more attractive design for some magnetics vendors but does result in a slight degradation in the CV regulation. See Appendix A for schematic, transformer construction and performance curves. The PCB layout includes provisions to allow a transformer based on an EE13 bobbin to be fitted. An EE16 core size was selected for this design based on feedback that this is generally the lowest cost core size. 4.1 Input Stage and 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, flame proof type, providing protection from primary-side short circuits and line surges and provides additional differential EMI filtering. The switching frequency of 42 kHz allows such a simple EMI filter to be used without the need for a Y capacitor while still meeting international EMI standards. It is recommended that RF1 be of wire wound construction to withstand input current surges while the input capacitor charges (metal film type are not recommended), and be compliant with safety flammability hazard requirements. Please consult your safety agency representative for requirements specific to your end-use application. Capacitors C1 and C2 are sized to maintain a minimum DC voltage of around 90 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.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
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. Once the output has reached regulation, PWM control maintains CV regulation by indirectly sensing the output winding voltage. Ideally the DC output voltage is equal to the bias voltage plus the forward drop of D6B multiplied by the transformer secondary winding to bias winding turns ratio minus the forward drop of D7. However, leakage inductance causes errors that vary with load, causing the output voltage to rise at noload. To give the best regulation, the bias and secondary windings should be physically close to each other in the transformer. Diode D6B 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 2.2 mA. 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). 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 0.8 mA, 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 (sense resistor, transistor, optocoupler and associated 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.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
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.
5 PCB Layout
Figure 4 - EP-54 Printed Circuit Board Layout and Dimensions (0.001 inches) (note: C7, R5 and R6 are not populated).
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
6 Bill Of Materials
Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Qty
1 2 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1
Reference
U1 C1, C2 C3 C4 C5 C6 D1-4 D5 D6B D7 J1 L1 RF1 R1 R2 R3 R4 T1
Description (Type)
LinkSwitch 4.7 F, 400 V (SHD Series) 4.7 F, 380 V 1 F, 50 V, general purpose 330 pF, 1000 V, Ceramic 220 nF, 50 V, Ceramic 330 F, 16 V, 117 m Rectifier 1 A, 600 V Rectifier Glass Passivated 1 A, 600 V 1 A, 600 V, Fast recovery, trr = 200 ns 1 A, 60 V Schottky Jumper, 24 AWG, bare (location D6A) 1.0 mH, 150 mA 8.2 Fusible 390 k, 1/4 W, 5% 100 , 5%, 1/4 W 15 , 5%, 1/2 W 6.81 k (1%), 1/4 W Custom EE16
P/N, Type
LNK520P 380VB4R7M8X11C 380VB4R7M8X11L ECA-1HHG010 ECK-D3A331KBP EEU-FC1C331 1N4005, 1N4007GP, 1N4937 11DQ06
Manufacturer
Power Integrations Sam Young UCC Panasonic (or generic) Panasonic (or generic) Generic Panasonic Diodes, Inc. (or generic) Generic Diodes, Inc. (or generic) International Rectifier (or generic) Any Tokin Vitrohm Any Any Any Any L.S.E. http://www.lishin.com
SBCP-47HY102B CRF0414 253-4/8R2, 5%
LSLA40319B-1
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
7 Transformer Specification
Note: To correctly center the output voltage over a junction temperature of 25 C to 65 C (approx ambient 0 C to 40 C), the design software and design methodology may produce a slightly different transformer design than the one shown here. 7.1 Electrical Diagram
Shield WDG #1
3
33T #32 AWG 1 1 7 Secondary 8T #30 T.I.W 6 WDG #3
WDG #2
Primary 100T #32 AWG 2
WDG #4
4 Shield & Bias 26T #31 AWG 5
Figure 5 - Transformer Electrical Diagram.
7.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-5 to Pins 6-10 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 2.52 mH, +/-10% 400 kHz (Min.) 80 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] Description Core: EE16, PC40EE16 TDK - ALG 252 nH/T2 Bobbin: Horizontal 10 pin (see Section 7.6) Magnet Wire: #32 AWG, Please see note on next page Foil: Tape Wrapped Copper Foil, 7. 5 mm +/-0.1 mm wide by 0.05 mm/2 mil thick, 35 mm +/- 0.5 mm length - see additional drawing Triple Insulated Wire: #30 AWG Magnet Wire: #31 AWG, Please see note on next page Tape: 3M 1298 Polyester Film (white) 322 mils (8.2 mm) wide by 2.2 mils thick Tape: 3M 1298 Polyester Film (white) 291 mils (7.4 mm) wide by 2.2 mils thick Tape: 3M 1298 Polyester Film (white) 586 mils (14.9 mm) wide by 2.2 mils thick Tape: 3M 1298 Polyester Film (white) 196 mils (5.0 mm) wide by 2.2 mils thick Barrier Tape: 2.0 mm wide, 0.15 mm thick, Please see the note on the next page Barrier Tape: 2.25 mm wide, 0.15 mm thick, Please see the note on the next page Glue AV118
Note: The transformer is an integral part of the EMI performance of this design. Changes to the transformer, even very minor, may have significant impact on both conducted and radiated EMI. More specific guidance is given below when attempting to repeat this transformer design.
1. Wire gauge selection for core cancellation, secondary and bias windings * The outside diameter of the wire can vary slightly due to variations in the insulation thickness although the bare copper area diameter is same. * Changing the wire gauge is acceptable to account for overall wire diameter differences. The wire gauge/size should be selected such that with the specified number of turns the winding completely fills one complete layer. * The bias winding can have the number of turns varied by up to 2 turns to make a complete layer if necessary but it is preferred to keep the turns as specified. * Winding information with wire gauge used should be indicated on sample report. 2. Primary winding * Use the same wire gauge/size as used for the core cancellation winding. 3. Barrier tape * Transformer vendors may have different thickness of barrier tape. * If the thickness is different, please make the height of the barrier tape the same or slightly higher than wire thickness used for that winding.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
7.4
Transformer Build Diagram
Shield & Bias #31 26T
5 4
2.0 mm Barrier Tape 2.25 mm Barrier Tape 4 Layers 4 Layers 2 layer Tape
1st layer: 14T 2 layer Tape
6 7
Secondary #30 TIW 8T 2.0 mm Barrier Tape 4 layer each
4 1
Wrapped Copper Foil 1 layer Tape
2
Sheild #32 33T
3 1
4 layer Tape
Figure 6a - Transformer Build Diagram.
KEY: = Electrical phasing = Mechanical start; reversed winding direction or same winding direction with bobbin rotated.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
41 mm +/- 0.5 mm 35 mm +/- 0.5 mm
14.9 mm
7.5 mm +/- 0.1 mm
Solder at center, Same height as wire Magnet wire, Item [3]
0.05 mm Thick Copper Foil Tape Item [9]
Fold
Figure 6b - Foil Construction Diagram.
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07-May-2004 7.5
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
Transformer Construction
Bobbin Preparation Shield Winding #1 Basic Insulation Terminate Shield Winding #1 Basic Insulation (continued) Primary Winding #2 Pull Pin 8-10 on bobbin [2] to provide polarization. Set bobbin with pins 1-5 on right hand side. Start at Pin 1. Wind 33 turns of item [3] from right to left in 1 layer across the entire width of the bobbin. Temporarily terminate wire on left hand side of bobbin. Apply 1 layer of tape item [7]. Terminate item [3] on pin 3. Cut pin 3 below termination to prevent contact with pcb trace. Apply an additional 3 layers of tape item [7]. Start at pin 2. Wind 100 turns of item [3] in 3 layers, plus 3 to 5 additional turns. Wind uniformly across the entire width of the bobbin with no empty space or gaps in any layer. Finish at pin 1. Assemble and apply foil shield [4] starting 3 mm from bottom side of bobbin [2]; such that foil termination wire aligns with pin 4. Insert the foil shield assembly [4] beneath a 10-15 mm long piece of tape (to hold in place). Wrap beneath 1 layer item [7] and terminate foil at pin 4. Apply 4 layers of item [11] on both sides of the bobbin ensuring no space to either bobbin wall. Change the bobbin [2] orientation with pins 6-10 on right hand side. Maintain same spindle rotation direction. Temporarily start at pin 1. Wind 8 turns item [5] in 1 layer from left to right. Wind uniformly across the entire width of the bobbin with no empty space or gaps in the layer. Finish at pin 7. Remove start from pin 1 and reattach to pin 6. Apply 2 layers tape item [7]. Apply 4 layers of item [11] on left side of the bobbin ensuring no space to bobbin wall. Apply 4 layers of item [12] on right side of the bobbin ensuring no space to bobbin wall. Start at pin 4. Wind 14 turns item [6] from left to right. Wind uniformly across the entire width of the bobbin with no empty space or gaps in the layer. Apply 1 layer of tape item [6], maintaining bias winding exit at edge of margin tape barrier. Continue winding item [6] from right to left. Wind a total of 26 turns item [6]. Finish on pin 5. Apply 2 layers of tape item [7]. Assemble and secure core halves with item [12]. Dip varnish and cure (do not vacuum impregnate).
Foil Shield
Margin Tape Bobbin Preparation Secondary Winding #3 Basic Insulation Margin Tape L and R Bias Winding #4 Basic Insulation Bias Winding #4 (continued) Outer Insulation Final Assembly
Page 15 of 40
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
7.6
Transformer Bobbin Drawing
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
8
Performance Data
All measurements performed at room temperature, 60 Hz input frequency. Output voltage was measured at the end of the DC output cable. Input power was measured with a Yokogawa WT120 power meter. 8.1 Efficiency
Efficiency at Full Load - 0.5A (measured at end of cable)
80% 75%
Efficiency (%)
70% 65% 60% 55% 50% 0 50 100 150 200 250 300
Input Voltage (VAC)
Figure 7 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
Efficiency vs. Output Current (measured at end of cable)
80% 75% 70% 65% 60% 55% 50% 0 0.1 0.2 0.3 0.4 0.5 0.6
Efficiency (%)
85 VAC 115 VAC 190 VAC 230 VAC 265 VAC
Load Current (A)
Figure 8 - Efficiency vs. Output Load, Room Temperature, 60Hz.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter 8.2 No-load Input Power
No-Load Pow e r Consumption
0.4
07-May-2004
0.3
Input Power (W)
0.2
0.1
0 0 50 100 150 200 250 300
Input Voltage (VAC)
Figure 9 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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07-May-2004 8.3 8.3 Regulation
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
8.3.1 Line and Load
V/I Characteristics (measured at end of cable)
11 10 9
Output Voltage (VDC)
8 7 6 5 4 3 2 1 0 0 0.1 0.2 0.3 0.4 0.5
85 VAC 115 VAC 190 VAC 230 VAC 265 VAC
0.6
0.7
Load Current (A)
Figure 10 - Load Regulation, Room Temperature, 50 Hz.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
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8.4 Thermal Performance The thermal images provide detail of the power supply operating component temperatures. The images were recorded after operating the unit for 12 hours at 85 VAC with an output load of 0.5 A at the maximum power point. This provides worst-case temperature rise on the LinkSwitch device. The top image details component temperatures of the assembly with the case removed. Hotspots are visible at LinkSwitch and output diode locations, which reached 53 C and 66 C, respectively. Operating within the closed case generated an internal temperature rise of +15 C. This additional temperature rise gives a maximum LinkSwitch and output diode case temperatures of 68 C and 81 C at 24 C ambient and 93 C and 106 C at 50 C ambient. These results are well within acceptable operating limits.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
Output Diode, D7
LinkSwitch
Output Diode, D7 LinkSwitch
Figure 11 - Thermal Image Measurements of Board and Sealed Adapter, 85 VAC, 5.5 V at 0.5 A, 23 C external ambient.
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9 Waveforms
9.1 Drain Voltage and Current, Normal Operation
Figure 12 - 85 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V, 5 s / div.
Figure 13 - 265 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V / div, 5 s / div.
9.2 Output Voltage Start-up Profile (Battery Load) The power supply was started up into an output load simulating a battery. Resistor RLOAD was reduced and confirmed start-up at voltages to 3 V. The battery model included series resistor value of 2.5 (RLOAD) and internal capacitor resistance of 0.5 (RINT_RES). The cable resistance RCABLE was set to zero as the load was attached to the end of the actual output cable.
Figure 14 - Battery load model.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
Figure 15 - Start-up Profile, 85 VAC. 0.5 V, 100 ms / div.
Figure 16 - Start-up Profile, 265 VAC. 0.5 V, 100 ms / div.
9.3
Drain Voltage and Current Start-up Profile
Figure 17 - 85 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V & 1 ms / div.
Figure 18 - 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V & 1 ms / div.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
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9.4 Load Transient Response (75% to 100% Load Step) The oscilloscope was triggered using the load current step as a trigger source.
Figure 19 - Transient Response, 85 VAC, 75-10075% Load Step. Top: Output Voltage, 200 mV, 2 ms / div. (AC coupled) Bottom: Load Current, 0.2 A / div. (DC coupled)
Figure 20 - Transient Response, 265 VAC, 75-10075% Load Step. Top: Output Voltage, 200 mV, 2 ms / div. (AC coupled) Bottom: Load Current, 0.2 A / div. (DC coupled)
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
9.5
Output Ripple Measurements
9.5.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 21 and Figure 22. 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 21 - Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).
Figure 22 - 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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9.5.2 Ripple Measurement Results All measurements were made with ripple probe at the end of the DC test cable. A resistive load was used in all cases.
Figure 23 - Ripple, 85 VAC, Full Load. 2 ms, 50 mV / div.
Figure 24 - Ripple, 230 VAC, Full Load. 2 ms, 50 mV / div.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
10 Conducted EMI
Conducted emissions tests were completed at worst-case conditions: 230 VAC at full load, 5.5 V/0.5 A. Measurements with Artificial Hand connection are less than those with floating DC output load resistor. The output DC cable was included. The test sample exhibits greater than 10 dBV margin below composite quasi-peak and average limits. This provides adequate margin to variation in transformer EMI characteristics. The results show significant attenuation in high frequency emissions. Composite EN55022B / CISPR22B conducted limits are shown.
Figure 25 - Conducted EMI, 230 VAC, Maximum DC Load, with Artificial Hand Connected to Output Load.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
Figure 26 - Conducted EMI, 230 VAC, Maximum DC Load, Output Load Floating.
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07-May-2004
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
11 Appendix A: EE16 Simple, No Foil, Construction
11.1 Introduction An alternative design utilizing an EE16 transformer with simplified construction is presented. The transformer uses integral bias and bifilar wound shields. These shields offer effective EMI attenuation with minimum additional transformer complexity. Reduced coupling between bias and secondary windings increases load regulation and no-load output voltage. A secondary snubber is required to reduce high frequency EMI. Efficiency is increased from 66% to 70%, due to a reduction in transformer primary-tosecondary leakage inductance. Appendix A presents schematic, bill of materials, transformer construction details and limited performance curves (including conducted EMI). All specification requirements are identical to those presented in Section 2. Unless specified, the performance of this prototype is similar to those presented earlier; including output ripple, waveforms and thermal performance. 11.2 Schematic The alternative EE16 transformer design is pin compatible with the EP-54 printed circuit board. Bias rectifier (D6B) and jumper (J1) are exchanged to maximize performance of the transformer bias shield. In addition, transformer primary shield (pin 3) is tied to bulk DC return. Component value changes are required to filter the increased leakage spike seen on the primary bias winding. This includes the clamp circuit (R1, C4) and primary bias circuitry (R3, R4). Component additions include secondary snubber circuit (R5, C7) and preload resistor (R6). 11.3 Bill of Materials Highlighted items are changes to previous design
Item
1 2 3 4 5 6 7 8 9 10
Qty
1 2 1 1 1 1 1 4 1 1
Reference
U1 C1, C2 C3 C4 C5 C6 C7 D1-4 D5 D6A
Description (Type)
LinkSwitch 4.7 F, 400 V (SHD Series) 4.7 F, 380 V 1 F, 50 V, general purpose 1000 pF, 1000 V 220 nF, 50 V 330 F, 16 V, 117 m 470 pF, 50 V Rectifier 1 A, 600 V Rectifier Glass Passivated 1 A, 600 V 1 A, 600 V, Fast recovery, trr = 200 ns
P/N, Type
LNK520P 380VB4R7M8X11C 380VB4R7M8X11L ECA-1HHG010 Ceramic Ceramic EEU-FC1C331 Ceramic 1N4005 1N4007GP 1N4937
Manufacturer
Power Integrations Sam Young UCC Panasonic (or generic) Any Any Panasonic Generic Diodes, Inc. (or generic) Any - generic Diodes, Inc. (or generic)
Page 29 of 40
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
11 12 13 14 15 16 17 18 19 20 21 1 1 1 1 1 1 1 1 1 1 1 D7 J1 L1 RF1 R1 R2 R3 R4 R5 R6 T1 1 A, 60 V Schottky Jumper, 24 AWG, bare (location D6B) 1.0 mH, 150 mA 8.2 Fusible 200 k, 1/4 W 100 , 1/4 W 200 , 1/4 W 5.9 k (1%), 1/4 W 51 , 1/4 W 5.1 k, 1/4 W Custom EE16 11DQ06
07-May-2004
International Rectifier (or generic) Generic Tokin Vitrohm Generic Generic Generic Generic Generic Generic HiCal www.hical.com
SBCP-47HY102B CRF0414 253-4/8R2, 5%
SIL6027D
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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07-May-2004
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
11.4 Transformer Specification 11.4.1 Transformer Winding
5 WD #1 38 T #33 AWG 4 Floating WD #3 11T #28X2 3 1 Primary 110 T #33 AWG 2
Figure 27 - Transformer Electrical Diagram, Alternate EE16.
7 WD #4 12 T #26 TIW Secondary 6
WD #2
11.4.2 Electrical Specifications
Electrical Strength Primary Inductance (Pin 1 to Pin 3) Resonant Frequency Primary Leakage Inductance 60Hz 1minute, from Pins 1-5 to Pins 6-7 All windings open All windings open Pins 6-7 shorted 3000 VAC 2.73 mH +/- 10% 510 kHz (Min.) 60 H (Max.)
Page 31 of 40
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
11.4.3 Transformer Build Diagram
6 Cut here 7
3
Tape Secondary Side
Primary Side
1
2
5 4
Figure 28 - Transformer Build Diagram, Alternate EE16.
11.5 Performance Data All measurements performed at room temperature, 60 Hz input frequency. Output voltage was measured at the end of the DC output cable. Input power was measured with a Yokogawa WT120 power meter.
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Page 32 of 40
07-May-2004 11.5.1 Efficiency
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
Efficiency at Full Load - 0.5 A (measured at end of cable)
80% 75%
Efficiency (% )y
70% 65% 60% 55% 50% 0 50 100 150 200 250 300
Input Voltage (VAC)
Figure 29 - Efficiency vs. Input Voltage, Alternate EE16, Full Load, Room Temperature, 60Hz.
Efficiency versus Output Current (measured at end of cable)
80% 75%
Efficiency (%)
70% 65% 60% 55% 50% 0 0.1 0.2 0.3 0.4 0.5 0.6
85 VAC 115 VAC 190 VAC 230 VAC 265 VAC
Load Current (A)
Figure 30 - Efficiency vs. Output Load, Alternate EE16, Room Temperature, 60Hz.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter 11.5.2 Line and Load Regulation
V/I Characteristics, Alternate EE16 Transformer (measured at end of cable)
11 10 9 8 7 6 5 4 3 2 1 0 0 0.1 0.2 0.3 0.4 0.5 0.6
07-May-2004
Output Voltage (VDC)
85 VAC 115 VAC 190 VAC 230 VAC 265 VAC
0.7
Load Current (A)
Figure 31 - Line and Load Regulation, Alternative EE16 Transformer Design.
11.6 Conducted EMI Conducted emissions were measured at the peak output power point at worst-case nominal line voltage, 230 VAC. Measurements consider both artificial hand (connected to DC output load terminal) and floating outputs. DC cable harness was included. The test sample exhibits greater than 10 dBV margin below composite Quasi-peak and Average limits. This provides adequate margin to variation in transformer EMI characteristics. The results show significant attenuation in high frequency emissions. Composite EN55022B / CISPR22B conducted limits are shown.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 34 of 40
07-May-2004
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
Figure 32 - Conducted EMI, Alternative EE16 Transformer design, 230 VAC, Maximum DC Load, with Artificial Hand.
Figure 33 - Conducted EMI, Alternative EE16 Transformer, 230 VAC, Maximum DC Load, Floating Output.
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EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
12 Revision History
Date 29-Sept-2003 01-Oct-2003 25-Feb-2004 07-May-2004 Author SH PV PV SH Revision 0.1 0.2 1.0 1.1 Description & changes First Draft Second Draft (Edits) Third Draft (Photo) Thermal Image (Labels)
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07-May-2004
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter NOTES
Page 37 of 40
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter NOTES
07-May-2004
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 38 of 40
07-May-2004
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter NOTES
Page 39 of 40
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-54 - LinkSwitch 2.75 W Low Cost Charger / Adapter
07-May-2004
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.
Power Integrations Worldwide Sales Support Locations
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