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Design Example Report
Title Specification Application Author Document Number Date Revision 0.7W Power Supply using LNK353P Input: 195 - 265 VAC Output: 7V / 0.1A TV Back Channel Power Supply Power Integrations Applications Department DER-109 October 26, 2005 1.0
Summary and Features * * * * * Low cost, low part count solution (only 18 components) <150 mW no-load input power Meets EN550022 and CISPR-22 Class B EMI with no Y1 safety capacitor Optimized switching speed yields excellent radiated EMI performance Small EE13 core size
The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com.
Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-109
TV Back Channel PSU
October 26, 2005
Table Of Contents
1 2 3 4 Introduction................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 Circuit Description ...................................................................................................... 5 4.1 Input and EMI Filtering ........................................................................................ 5 4.2 Output Rectification and Filtering ........................................................................ 5 5 PCB Layout ................................................................................................................ 6 6 Bill Of Materials .......................................................................................................... 6 7 Transformer Specification........................................................................................... 7 7.1 Electrical Diagram ............................................................................................... 7 7.2 Electrical Specifications....................................................................................... 7 7.3 Materials.............................................................................................................. 7 7.4 Transformer Build Diagram ................................................................................. 8 8 Performance Data ...................................................................................................... 9 8.1 Load and Line Regulation ................................................................................... 9 9 Thermal Performance............................................................................................... 10 10 Waveforms............................................................................................................ 10 10.1 Output Voltage Start-up Profile ......................................................................... 10 10.2 Output Ripple Measurements............................................................................ 11 10.2.1 Ripple Measurement Technique ................................................................ 11 10.2.2 Measurement Results ................................................................................ 11 11 Conducted EMI ..................................................................................................... 12
Important Notes: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolated source to provide power 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.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 2 of 14
DER-109
TV Back Channel PSU
October 26, 2005
1 Introduction
This document is an engineering report describing a single input, 0.7W output power supply utilizing a LinkSwitch-HF LNK353P 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 14
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DER-109
TV Back Channel PSU
October 26, 2005
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage Output Ripple Voltage Output Current Symbol VIN fLINE Min 195 47 Typ Max 265 64 Units VAC Hz W V mV A Comment
2 Wire - no P.E.
VOUT1 VRIPPLE1 IOUT1
7 50 0.1
10% 20 MHz bandwidth
Total Output Power Continuous Output Power Efficiency Environmental Conducted EMI Safety External Ambient Temperature
POUT
0.7 60
W %
Measured at POUT (0.7 W), 25 oC
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
>5 dB margin
TAMB
0
50
o
C
Free convection, sea level
Page 4 of 14
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-109
TV Back Channel PSU
October 26, 2005
3 Schematic
1
L
RF1
8.2 2.5 W
D1
1N4937
L1
2700 uH
2 R6
100 k
T1 8
D2
UF4002
L2
3.3 uH
1 C6
100 uF 10 V 7V,100mA
C9
1 nF 1 kV
3 4 1 2 N.C.
C3
220 uF 10 V
5
1 VR1
1N5234B 6.2V R2 EE13 220 0.125 W 0V
D3
1N4937
C5
2.2 uF 400 V
C12
2.2 uF 400 V
D FB BP
PC817D
U1
S
U2B U2A
PC817D
LNK353P
C7 1
N 100 nF 50 V
Figure 2 - Schematic
4 Circuit Description
A simple, low cost, 0.7 W power supply is achieved with minimum parts count - made possible by the LinkSwitch power device. The integrated 700 V switching MOSFET and On/Off control function achieve high efficiency operation without a bias winding. The EE13 transformer uses a bobbin with extended creepage to meet safety spacing requirements. The transformer operating flux density is low (1250 Gauss, 125 mT) to reduce audio emissions, due to On/Off control, to acceptable levels. This combined with standard dip varnishing of the transformer virtually eliminates audible noise. 4.1 Input and EMI Filtering AC input differential filtering is accomplished with a filter formed by C5/C12 and L1. The inductor L1 is sleeved to also allow it to function as a fuse. An additional diode may be added to the Neutral phase in applications where lower EMI margins and/or an increased input surge withstand is required. 4.2 Output Rectification and Filtering Output rectification and filtering is achieved with output rectifier D2 and filter capacitor C3.
Page 5 of 14
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-109
TV Back Channel PSU
October 26, 2005
5 PCB Layout
Figure 3 - Printed Circuit Layout. (Not all parts are fitted due to Spec. change.)
6 Bill Of Materials
Item Qty Value 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 220 uF 2 2.2 uF 1 100 uF 1 100 nF 1 1 nF 2 1N4937 1 UF4002 Description 220 uF, 10 V, Electrolytic, Low ESR, (6.3 x 11) 2.2 uF, 400 V, Electrolytic, (8 x 11.5) Part Reference Mfg C3 C5 C12 Rubycon Mfg Part Number 10YXG220M6.3X11
United Chemi-Con SMG400VB2R2M8X11LL United Chemi-Con KME10VB101M5X11LL Panasonic Panasonic Vishay Vishay Epcos API Delevan ECU-S1H104KBB ECK-D3A102KBP 1N4937 UF4002 B78148-S1275-J 1025-32K
100 uF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) C6 100 nF, 50 V, Ceramic, X7R 1 nF, 1 kV, Disc Ceramic C7 C9
600 V, 1 A, Fast Recovery Diode, 200 ns, DO-41 D1 D3 100 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 D2 L1 L2 RF1 R2 R6 T1 U1 U2 VR1
1 2700 uH 2700 uH, 80 mA, 40 Ohm, Axial Ferrite Inductor 1 3.3 uH 1 8.2 1 220 1 100 k 1 EE13 3.3 uH, 0.285 A, Iron Core 8.2 Ohm Fusible Resistor, 2.5W 220 R, 5%, 1/8 W, Carbon Film 100 k, 5%, 1/4 W, Carbon Film Bobbin, EE13, Horizontal, 8 pins
Yageo Yageo Hical Magnetics
CFR-12JB-220R CFR-25JB-100K
1 LNK353P LinkSwitch-HF, LNK353P, DIP-8B 1 PC817D Opto coupler, 35 V, CTR 300-600%, 4-DIP 1 1N5234B 6.2 V, 5%, 500 mW, DO-35
Power Integrations LNK353P Isocom, Sharp Microsemi ISP817D, PC817X4 1N5234B
Page 6 of 14
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DER-109
TV Back Channel PSU
October 26, 2005
7 Transformer Specification
7.1 Electrical Diagram
2 Primary 80 Turns 0.15mm Magnet Wire 8 3 4 Balance 15 Turns 2*0.20mm Magnet Wire bifilar Core 21 Turns 2*0.15mm Magnet Wire N.C. bifilar 7V 15 Turns 0.25mm Triple Isolated Wire 5 1 2
EE13
Figure 4 - Transformer Electrical Diagram
7.2
Electrical Specifications
60 Hz 1 min, from Pins 2-3 to Pins 5-8 From pins 3-2, all other windings open From pins 3-2 with and 5-8 shorted 3000 VAC 650 uH, -/+12% 30 H (Max.)
Electrical Strength Primary Inductance Primary Leakage Inductance
7.3
Materials
Description 2 Core: EE13, PC40EE13, TDK - ALG 102 nH/T Bobbin: Horizontal 8 pin Magnet Wire: 0.15mm Magnet Wire: 0.2mm Triple Insulated Wire: 0.25mm Tape: 3M 1298 Polyester Film (white) 7.9mm wide by 2.2 mils thick Varnish (dip)
Item [1] [2] [3] [4] [5] [6] [7]
Page 7 of 14
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DER-109
TV Back Channel PSU
October 26, 2005
7.4
Transformer Build Diagram
PIN 8 PIN 5 PIN 4 PIN 1 PIN 2
7V Secondary W inding
Balance W inding TAPE Primary W inding
PIN 3 PIN 2 N.C.
Core Shield
Figure 5 - Transformer Build Diagram
Page 8 of 14
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DER-109
TV Back Channel PSU
October 26, 2005
8 Performance Data
All measurements performed at room temperature, 50 Hz input frequency. 8.1 Load and Line Regulation
5 4 Tolerance of Nom. Value in % 3 2 1 0 -1 -2 -3 -4 -5 190 200 210 220 230 Input Voltage in V 240 250 260 270
Figure 6 - Line Regulation, Room Temperature
5 4 Tolerance of NOM. Value in % 3 2 1 0 -1 -2 -3 -4 -5 Load Percent of NOM. Load in % 0 20 40 60 80 100 120
Figure 7 - Load Regulation, Room Temperature
Page 9 of 14
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-109
TV Back Channel PSU
October 26, 2005
9 Thermal Performance
(Measured with Testo Infrared Thermometer)
Temperature (C) Item Ambient Transformer (T1) LinkSwitch (U1) Resistor (R6) Rectifier (D2) 195 VAC 25 33.5 32 31 35 265 VAC 25 32.5 39 34.5 37
10 Waveforms
10.1 Output Voltage Start-up Profile
Figure 8 - Start-up Profile, 230 VAC VOUT, 2 V & 1 ms / div.
Page 10 of 14
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DER-109
TV Back Channel PSU
October 26, 2005
10.2 Output Ripple Measurements 10.2.1 Ripple Measurement Technique A ripple probe, which included 1.0 F Aluminum electrolytic capacitor in parallel with 0.1F ceramic capacitor, was used for all ripple measurements. The probe was located at the end of the DC output cable assembly.
Figure 9 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added.)
10.2.2 Measurement Results
Figure 10 - Ripple, 195 VAC, Full Load. 100us, 10 mV / div
Figure 11 - Ripple, 265 VAC, Full Load. 100us, 10 mV / div
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 11 of 14
DER-109
TV Back Channel PSU
October 26, 2005
11 Conducted EMI
Figure 12 - Conducted Emissions without Artificial Hand QP/AVG: 230 VAC, Full load, Neutral
Figure 13 - Conducted Emissions without Artificial Hand QP/AVG: 230 VAC, Full load, Line
Page 12 of 14
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-109
TV Back Channel PSU
October 26, 2005
Revision History
Date 10-26-05 Author HM Revision 1.0 Description & changes Initial Release Reviewed KM/JC/VC
Page 13 of 14
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-109
TV Back Channel PSU
October 26, 2005
For the latest updates, visit our website: www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NONINFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, EcoSmart, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)Copyright 2005 Power Integrations, Inc.
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