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title engineering prototype report for ep-1 6 - 2.75 w charger/adapter using lnk501 ( linkswitch ? ) specification 85 vac to 265 v a c input, 5.5 v, 500 ma output application low cost charger/adapter author pi applications document number EPR-16 date 17-may-04 revisio n 1.6 features ? very low co st, low component count charger/ada pter ? replaces linear transf o rmer based solution s ? extre m ely simple circuit configuratio n designed f o r high volume, low cost manufacturing ? no surface mount comp onents required ? small ee13 transformer allows compact size ? approximat e constant voltage, constant current (cv/cc) pri m ary sensed outp u t characteristic ? no optocoupler or sense resistors required ? efficiency gr eater than 7 1 % ? no-load power consumption <300 mw at 265 vac ? no y1 safety capacitor r equired ? only transformer bridges primary-to -secondary safety barrier ? ultra low leakage design (<5 a) t he products and ap pl icatio ns il lustra te d here i n ( i ncl udi ng c i rcuits e x terna l to th e p r oducts and transform e r constructio n ) ma y be c o vere d b y o ne or m o re u.s. and for e ig n pate n ts or potenti a ll y b y pen din g u.s. a nd fore ign patent app licati ons ass i g ned t o po w e r in tegr ations. a c o m p lete list of po w e r integr atio n s ? pate n ts ma y be fo un d at ww w.pow erint.com . po w e r integrations 5245 hellyer avenue, san jo se, ca 951 38 usa. applicatio ns hotline: tel: +1 40 8 414 9 660 fax: +1 408 414 9 7 6 0 ww w.po we rin t.com
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 table of contents 1 introducti on ................................................................................................................. 4 2 power supply s pecificat ion ........................................................................................ 5 3 schemat ic ................................................................................................................... 7 4 circuit desc ription ...................................................................................................... 8 4.1 input st age .......................................................................................................... 8 4.2 linkswitch operation .......................................................................................... 9 4.3 transforme r ....................................................................................................... 10 4.4 clamp and feedback componen ts ................................................................... 10 4.5 output st a g e ..................................................................................................... 11 5 pcb lay out .............................................................................................................. 12 6 bill of ma te rials ........................................................................................................ 13 7 transforme r .............................................................................................................. 14 7.1 transforme r winding ......................................................................................... 14 7.2 electrical spec ifications ..................................................................................... 14 7.3 material s ............................................................................................................ 15 7.4 transforme r build diagram ............................................................................... 15 7.5 transforme r cons tructi on .................................................................................. 16 8 performanc e data .................................................................................................... 17 8.1 line and load r egulation.................................................................................. 17 8.2 efficienc y ........................................................................................................... 18 8.3 no-load input power ........................................................................................ 18 9 wavefo rms ............................................................................................................... 19 9.1 drain voltage and cur r ent wave forms .............................................................. 19 9.1.1 90 vac, normal o per atio n ......................................................................... 19 9.1.2 265 vac, normal o peratio n ....................................................................... 19 9.2 output voltage star t-u p pr ofile .......................................................................... 20 9.3 load transient response (0. 25 a to 0.5 a load st ep) ..................................... 20 9.4 output ripple m easurement s ............................................................................ 21 9.4.1 ripple measurement t e chnique ................................................................ 21 9.4.2 output volt age rippl e ................................................................................ 22 9.5 thermal meas urements .................................................................................... 23 9.6 conducted emi .................................................................................................. 24 9.6.1 optional components with artific i al hand ................................................. 25 9.6.2 optional components without artificial hand ............................................ 25 9.6.3 optional components removed wi th artifici al h and ................................. 26 10 appendix a ? ep-16 enclos ure opening procedur es .............................................. 27 10.1 method 1 - non- destructi ve ............................................................................... 27 10.2 method 2 - dest ructive ...................................................................................... 27 11 appendix b ? lnk520p in the high-side confi guration .......................................... 28 11.1 introducti on ........................................................................................................ 28 11.2 comparison of ln k501 and ln k520 ................................................................ 28 11.3 circuit ch anges ................................................................................................. 29 11.4 performance data ............................................................................................. 30 11.4.1 line and load regu lation .......................................................................... 30 11.4.2 efficienc y .................................................................................................... 31 page 2 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 11.4.3 no-load input power .................................................................................. 32 11.5 emi perfor mance ............................................................................................... 33 12 revision hi story ........................................................................................................ 34 important note: although the ep-16 is designed to satisfy safety isolation requirements, this engineering prototype has not been agency approved. theref ore, all testing should be per f ormed using an is olation transforme r to provide the ac input to the prototype board. page 3 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 1 introduct i on this document is an engineer ing report giving performance ch aracteristics of a 5.5 v, 500 ma charger/adapter. the charger uses linkswitc h ? an integrated ic combining a 700 v high voltage mosfet, pw m controller, start-up, ther mal shut down and fault protection circuitry. the cont roller provides both duty cycle and current limit control to yield a constant voltage/cons tant current output characte ristic without secondary-side sensing. t h is power supply is designed to provide a c o st effective replacem ent for linear transformer based chargers and adapters while prov iding th e additional benefits of universal input range and high energy efficiency. this document contains the power supply spec ific ation, schematic, bill of materi als, transformer documentation, printed circ uit board layout , and performance data. figure 1 ? ep-16 popul ated circuit bo ard. figure 2 ? ep-16 assem b led into ca se with ca ble (ba rrel ?
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 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 prot ective ground freq uen cy f line 4 7 5 0 / 6 0 6 4 h z no-l oad inp u t power (265 vac) 0.3 w outpu t output voltag e v out 5 . 0 5 . 5 6 . 0 v at peak output p o wer point output rip p le voltage (re s. load) v ripple r 3 0 0 m v resistive load, p eak po w e r output rip p le voltage (bat. load) v ripple b 1 5 0 m v batter y load , pea k pow e r output cu rre n t 1 i out 4 0 0 5 0 0 6 0 0 m a total ou tpu t po w e r contin uou s o u tput powe r p out 2 2 . 7 5 3 . 6 w efficiency ?
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 figure 4 ? battery model used for te st ing. note: ep-16 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 c3 to 1
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 3 schematic figure 5 ? ep-16 lo w co st, 2.75 w lin k switch cell phone cha r g e r sch e matic. optional components l2, c6 and r4 may be fi tted to the board t o improve radiated emi. the effect of these components is shown in the ?conducted emi results? section of this document. optional component r3 may be fitted in plac e of l1 in applic ations where conducted emi is filtered externally (e.g. in an embedded s ystem). in this case a 0 ? ? ?
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 4 circuit descriptio n the schem atic shown in f i gure 5 provides a cv/cc ( c onstant volt age/cons tant current) type output characteristic from a universal input voltage range of 85 vac to 265 vac. the nominal peak power point at the transition from cc to cv is 5.5 v at 500 ma. the precis e output envelope specific ation is shown in f i gure 3. 4.1 input stage the incoming ac is rectified and filtered by d1-4, c1 and c2. resistor rf1 is a flameproof fusible type to protect against faul t conditions and is a requirement to meet safety agency fault testing. this componen t should be a wire wound type t o withstand input current surges while the input capac it ors charge on applic ation of power or during withstand line-transient testing. metal film type resistors are not recommended, they do not have the transient dissipatio n capabilities required and ma y fail prematurely in the field. lower values increase the resistor dissipation (v2/r pow er term) during transients, increasing resistor stress, wh ile higher values increase steady state dissipation (i2r power term) and reduce efficiency. if a suitable flame proof resistor cannot be f ound (during failure flam e proof resistors do not emit flames, smoke or incandescent material that ma y damage transformer insulation), then a standard fusible type may be used as long as a pr otectiv e heat s h rink sleeve is placed over t he resistor. please c ons ult with a safety engi neer or local safety agency. the value of c1 and c2 were selected to prov ide the smallest standard values to meet 3 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 4.2 linkswitch operation when power is applied to t he supply, high voltage dc appe ars at the d r ain pin of linkswitch (u1). the control pin capacitor c3 is then charged through a switc hed high v o ltage current source connected internally be tween the drain and control pins. when the control pin voltage reaches approximately 5.7 v relative to the source pin, the int e rnal current source is turned off. t he internal control circuitry is activated and the high voltage in t e rnal mosfet starts to swit ch, using the energy in c3 to power th e ic. as the current ramps in the pr imary of flyback transformer t1 , energy is stored. this energy is delivered to the output when the mosfet turns off ea ch cycle. the secondary of the transforme r is rectified and f iltered by d6 and c5 to provide the dc output to the load. control of the output characteri stic is entirely sensed from t he primary-side by monitoring the primary-side v or ( v oltage output reflected). while t he output diode is conducting, the voltage acr o ss the transformer primary is equal to the output voltage plus diode drop multiplied by the turns ratio of the transformer. since the links witch is connect e d on the high side of the transformer, the v or can be s ensed directly. diode d5 and capacit or c4 fo rm the primary clamp network . the voltage held across c4 is essentially the v or with an error due to the parasitic leakage inductance. the l i nks witch has three operating modes determined by the c u rrent flowing into the control pin. during start-up, as the output v o ltage, and therefore the reflected voltage and voltage across c4 increases, the feedback current increases from 0 to approxim ately 2 ma through r1 into the control pin. the inter nal current limit is increased during this period until reaching 100%, providing an approximately constant output current. once the output voltage reaches the regulated cv value, t he output voltage is regulated through control of the duty cycle. as th e current into the control pin exceeds approximately 2 ma, t he duty cy cle begins to reduce, reaching 30% at a control pin current of 2.3 ma. if the duty cycle reaches a 3% threshold, the switching frequency is reduced, which reduces energy consumption under light or no load conditions. as the out put load increases be yond the peak power point (def ined by ?li2f) and the output volt age and v or falls, the reduced control pin current will lower the internal current providing an a pproximately constant current output characteristic. if the output load is further increas ed and the output volt age falls further to below a control pi n current of 1 ma, the control pin capacitor c3 will discharge and t he supply will enter auto-restart. page 9 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 4.3 transformer the transformer is designed to always be disc ontinuous; all the energy is t r ansferred to the load during the mosfet off time. t he energy stored in the transformer during discontinuous mode operati on is ?li2f, where l is the primary inductanc e, i2 is the peak primary current squared and f is the switching frequency. since the value of linkswitch c u rrent limit and frequency directly determines the peak power or cv/cc transition point in the output characteristic, the parameter of current squared times frequency is defi ned in the datasheet. this parameter, toget her with the output power, is used to spec ify the transfo rmer primary inductance. with a primar y inductance tolerance of ? 4.4 clamp and feedback components diode d5 should either be a fast (t rr <250 ns) or ultr a-fast type to prevent the voltage across lin k switch from reversing and ringing below gr ound. a fast diode is preferred, being lower cost. leakage induc t ance is filt ered by r2, the optimum value providing the straightest cc characteristic. capac itor c4 is typic a lly fixed at 0.1 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m ?
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter r1 was selected to program t he peak power point to be 500 ma when a transformer w i t h a nominal l p value was used. initial values ar e selected using the expression (from power integrations app lication note, an-35): r1 ? ? ? ? ? 4.5 output stage diode d6 should be rated for 80% of applied reverse voltage and thermally for average current multiplied by forward volt age at maximum am bient. here a 1 a, 6 0 v schottky diode was used to reduce the lo sses and improve efficiency, al t hough fast or ultra-fast pn diodes are acceptable. a snubber formed by c6 and r4 may be fi tted ac ross d6 to improve r adiated emi performance. capac itor c5 should be rat ed for output voltage and ripple current. depending on th e application, the designer may choo se not to derate for ripple curr ent. if the applic ation is battery charging of equipment such as pd as or cell phones, the duty cycle of operation at high ripple current is lik ely to be low, perhaps only 1 hour per day. in this case the capacitor temperature can be allowed to ris e significan tly during c har ging wit hout concern for the overall capac itor lifetime. page 11 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 5 pcb la yout figure 5 ? ep-16 printe d circuit board layout and dimensi o n s (0. 001 in che s ). page 12 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 6 bill of materials i t e m q u a n tit y referen c e part de scrip t i o n 1 2 c 1 , c 2 4.7 ? ?, ? ?
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 7 t r ansformer 7.1 transformer winding 4 1 4 3 5 6 s h ie ld pr im ar y sec o n dar y 12 t # 30 a w g 104 t # 34 a w g 15 t # 30 t .i. w wd g # 3 wd g # 1 wd g # 2 x 2 figure 6 ? transfo rme r wi nding diag ra m. 7.2 electrical specifications electrical str e ngth 60 hz 1 min, from pins 1 - 3 to pins 5-6 3000 vac primar y indu ctan ce (pin 1 to pin 3) all winding s o pen 2.55 mh reso nan t fr equen c y all winding s o pen 300 khz (min .) primar y leakage inducta nce (pin 1 to pin 4) pins 5-6 sh orted 50 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 7.3 m a t e rials i t e m d e s c r i p t i o n [1] core: ee13, pc40ee13, t d k ? alg 19 0 nh/t 2 [2] bobbin: ho ri zontal 8pin ? p i ns 7 an d 8 re moved [3] magnet wire: #34 awg [4] magnet wire: #30 awg [5] triple in sulat ed wire: #30 awg. [6] tape: 3m 12 98 polyeste r film (white ) 3 20mils wide b y 2.2 mils thick [7] tape: 3m 12 98 polyeste r film (white ) 2 90mils wide b y 2.2 mils thick [8] glue av118 [9] cop per tap e 6mm +/- 0.1 5 mm wide by 0.076 mm thick design no tes: power integrations device lnk501 frequency of operation 42 khz m o d e d i s c o n t i n u o u s peak current 0.263 a reflected voltage (secondary to primary) 48 v maximum dc input voltage 370 v minimum dc input votlage 90 v 7.4 transformer build diagram figure 7 ? ep-16 tran sformer build di a g ram. page 15 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 7.5 transformer construction seconda r y winding start at pin 4 temporarily. wind 1 5 turn s of item [5] from right to left with tight tension. wind unifo rmly, in a single layer acro ss entire width of bobbi n. finish on pin 6. basic insula tion 1 layer of tape [6] for ins u lation. seconda r y winding cha nge the start pin con n e c tion of se co ndary wi ndin g from pin 4 to pin 5. basic insula tion 1 layer of tape [6] for ins u lation. canc ellation winding start at pin 3. wind 12 tu rn s of bifilar item [4] from right to left with tight tensio n. win d uniformly, in a singl e layer, acro ss e n tire width of b obbin. finish o n pin 4. basic insula tion 1 layer of tape [6] for ins u lation. primar y winding 2 2/3 la y e r start at pin 4. wind 10 4 turns of item [3] from right to l e ft in 2 and 2/3 layers a c ro ss entire width of bobbin. wi nd all layers with tight tension. finish o n pin 1. outer insulation 10 layer of ta pe [7] for insu lation. core ass e m b ly a sse mble a n d se cur e co re halv e s u s ing it em [ 8 ] flux / belly band place item [9] aroun d outsi de of windi ng s and core ha lves with tight tensio n. make electri c al co nne ction to b and from pi n 3 usin g item [4]. basic insula tion 2 layers of tape [6] for ins u lation. crop unus e d pins remove pi ns 7 and 8 note: the transform er is an integral part of the emi performance of this design . changes to the transform er m a y have signif i cant im pac t on both conducted and radiated emi. page 16 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 8 performance dat a all measurements were performed at room te mperature, 60 hz i nput frequency unles s otherwise specified. the output voltage was measured at the e nd of the output cable. efficiency results therefore include output cable loss es . input power measurements were taken us i ng a yokogawa wt200 si ngle phase digital power meter. for the no-load measuremen t, the current scale was set to 10 ma. 8.1 line and load regul ation r e gulation c u r v e 0 1 2 3 4 5 6 7 8 9 10 0 100 200 300 400 500 600 load current ( m a ) output voltage (vdc) 85 v a c 115 v a c 190 v a c 230 v a c 265 v a c figure 8 ? lo ad re gulatio n at selected input voltage s. page 17 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 8.2 efficiency efficiency vs. output current 0 10 20 30 40 50 60 70 80 0 100 200 300 400 500 600 loa d cur r e nt ( m a ) efficiency (%) 85 v a c 115 v a c 190 v a c 230 v a c 265 v a c figure 9 ? efficien cy vs. output curre n t at selected in put voltages. 8.3 no-load input power no- load consum pt i o n 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 80 100 120 140 160 180 200 220 240 260 280 a c input volt a g e ( v a c ) input power (mw) figure 10 ? zero l oad in put powe r vs. input line voltage. page 18 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 9 w aveforms 9.1 drain voltage and current waveforms 9.1.1 90 vac, normal operation figure 11 ? lin k sw itc h (u 1) v drain and i drain wav e forms v in = 90 vac, i o = 500 ma. ch.1: lin k swi t ch drain - sou r ce volta ge (100 v/div). ch.3: lin k swi t ch drain-sourc e current (0.1 a/div). 9.1.2 265 vac, normal operation figure 12 ? lin k sw itc h (u 1) v drain and i drain wav e forms v in = 265 vac, i o = 500 ma. ch.1: lin k swi t ch drain - sou r ce volta ge (100 v/div). ch.3: lin k swi t ch drain-sourc e current (0.1 a/div). page 19 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 9.2 output voltage start-up profile figure 13 ? output voltag e at start-up, battery model, v in = 90 vac, p out _ max . figure 14 ? output voltag e at start-up, battery model, v in = 265 vac, p out _ m a x . 9.3 load tran sient response (0.25 a to 0.5 a load step) figure 15 ? dynami c loa d tran sie n t 0.25 a to 0.5 a step at v in = 90 vac. ch.3: output voltage (5 00 mv/div). figure 16 ? dynami c loa d tran sie n t 0.25 a to 0.5 a step at v in = 265 vac. ch.3: output voltage (5 00 mv/div). page 20 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 9.4 output ripple m easurements 9.4.1 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 pi ckup. det a ils of the probe modification are provided in figur e 17 and figure 18. the 5125ba probe ad apter is affixed with two capac itor s tied in parallel acros s the probe tip. the capacitors include one (1) 0.1 probe ground probe tip figure 17 ? oscillo scope probe prepa red for rip p le measurement . (end cap an d groun d lead remove d). figure 18 ? oscillo scope probe with probe ma ster 5 125ba bnc adapter. (modifie d wit h wire s for p r obe groun d for rip p le mea s ureme n t and two parall e l de co upling capa cit o rs a dde d). page 21 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 9.4.2 output voltage ripple measurements are shown for both resistiv e and battery model loads (figure 4). figure 19 ? output voltag e rippl e (resistive) at v in = 115 vac, v o = 5.2 v, i o = 500 ma (scal e : 100 mv/div). figure 20 ? output voltag e rippl e (resistive) at v in = 230 vac, v o = 5.3 v, i o = 515 ma (scal e : 100 mv/div). figure 21 ? output voltag e rippl e (battery) at v in = 115 vac, vo = 5.2 v, io = 500 ma (scal e : 100 mv, 5 ms,10 0
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 9.5 thermal m easurements figure 23 shows two thermal image phot ographs with a visual photograph as a reference. with the board in free air, the first thermal image sho w s the hottest component s were lin k switch and the output diode, reaching 4 7 linkswitch output diode linkswitch output diode thermocouple inser t ed into case above linkswitch figure 23 - t herm a l image measu r em en ts of board a nd sealed ad apter, 85 va c input, 5.3 v, 500 ma output, 22 page 23 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 9.6 conducted em i all measur ements were taken at the peak output power point with a line voltage of 230 vac. this line voltage repr esents the worst case; results are lower at 115 vac. limts shown are for en55022b / cispr22b final meas urements were taken in all cas e s, representing the wors t case of both phas e and indicated as either ?x? on quasi peak results or ?+? on average results. results wit h and with out the optional comp onent s l2, r4 and c6 are shown to illustrate the improvement in radiated em i (50 mhz to 60 mhz region). in all cases, a 10 db or greater margin was obtained. page 24 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 9.6.1 optional components with artificial hand figure 24 ? en550 22 b / cispr22 b, v in = 230 vac, 60 hz line , peak powe r point, output retu rn con n e c ted to artificial hand input on lisn. 9.6.2 optional components wi thout artificial hand figure 25 ? en550 22 b / cispr22 b, v in = 230 vac, 60 hz line , peak powe r point, output floati ng. page 25 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 9.6.3 optional components removed with artificial hand figure 26 - e n 55 022 b / cispr22 b, v in = 230 vac, 60 hz li ne, peak powe r point, output retu rn con n e c ted to artificial hand input on lisn. figure 27 - e n 55 022 b / cispr22 b, v in = 230 vac, 60 hz li ne, peak powe r point, output retu rn floating. page 26 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 10 appendix a ? ep-16 enclos ure opening procedures 10.1 m e t hod 1 - non-destructive step 1: insert thin bla ded sc re wd riv e r s int o slot s in the ac con n e c t portion of ca se. mak e cert ai n scre wd river is on top of plasti c tab. step 2: insert thin bla ded sc re wd riv e r b e twee n two halves of the ca se an d twist. case will pop a part . rep eat on ot her si de an d pull to s e parate. figure 28 ? non - de structi v e openin g o f ep-16 ca se . 10.2 m e t hod 2 - destructive step 1: usi ng dia gon al cutter clip plasti c and lift up as sho w n. re pe at on both sid e s of ca se (4 pl ace s ). ca se will then sepa rate. figure 29 - destru ctive op ening of ep-1 6 ca se. page 27 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 11 appendix b ? lnk520p in the high-side configuration 11.1 introduction in applications with looser cv /cc limits, the lower cos t linkswitc h lnk520p can be used in the high-side configuration, which may be attractive since the internal mosfet drive has been optimized, typically reducing radiated emi by 6 db to 10 db. this appendix details the changes necessary to replace u1 from a lnk501 to a lnk520 device. in addition, resultant changes in the output char acteristic, efficiency, no-load consumption and radiated emi are presented. 11.2 comparison of lnk501 and l nk520 the lnk501 was designed for use in a hi gh-side configuration, using the v or across the primary winding to provide output sensin g and feedback. since the feedback signals differ, the internal control characteristi cs of the lnk501/lnk520 have therefore been specifically optimized for hi gh-side/low-side operation, re spectively. the lnk520 was designed for use in a low-side configuration, using an auxiliary or bias winding to sens e the output and provide f eedback. in addition, the lnk520 has a wider i 2 f data sheet tolerance than the lnk501. when us ing the lnk520 dev ice in the high- side c onfiguration, the output voltage tends to be higher at no-load and the cc region of the output characteri stic is les s linear, the output current increas ing as the output voltage reduces. the wider i 2 f specification of the lnk520 increases the cc tole rance from approximately po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 11.3 circuit changes all components other than those listed below, inc l uding the trans former, are identical to the original ep-16 design. the modified ep -16 schematic is shown in figure 30. u1 lnk501p replaced wit h lnk520p. r1 20.5 k ? ?. ? ?. figure 30 ? modified ep-16: low co st, 2.75 w cell phone cha r g e r using the lnk52 0 p. page 29 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 11.4 performance data 11.4.1 line and load regulation the existing limits for the ep-16 (lnk501) design are shown for reference. key differences to note ar e the higher no-load v o lt age, lower voltage at t he peak power point and the increase in the output current as the voltage falls in the cc region. the lower voltage at the peak po wer point has the additional effect of increasing the current at the power point. this c ould be adj usted by increasing the feedback resistor r1, which would also increase the no- load voltage and no-lo ad input power. 0 1 2 3 4 5 6 7 8 9 10 11 0 1 00 2 0 0 3 00 40 0 5 00 6 0 0 7 0 0 8 0 0 lo a d c u rrent ( m a ) o u tp u t vo ltag e (vdc) 85 v a c 115 v a c 190 v a c 230 v a c 265 v a c ln k 5 01 ( m ax ) ln k 5 01 ( m i n ) ln k 5 20 ( m i n ) ln k 5 20 ( m ax ) figure 31 ? l oad regulati on at selecte d input voltages (ep - 16 using the l n k 520p). page 30 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 11.4.2 efficiency efficiency is slightly lower only due to t he lower output voltage at the peak power point. resistor r1 could be increased s lightly to r a ise the p e ak power point output voltage a n d hence, efficiency, if desired. 0. 00 10 . 0 0 20 . 0 0 30 . 0 0 40 . 0 0 50 . 0 0 60 . 0 0 70 . 0 0 80 . 0 0 0 1 00 2 0 0 3 0 0 40 0 5 0 0 6 0 0 7 00 80 0 9 0 0 10 00 lo a d c u r r e nt ( m a ) efficien cy (%) v i n = 85 v a c v i n = 11 5 v a c v i n = 19 0 v a c v i n = 23 0 v a c v i n = 26 5 v a c figure 32 ? efficiency vs. output cu rre n t at selected input voltages. page 31 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 11.4.3 no-load input power no-load input power is slightly higher due to the higher no-load voltage. howev e r at 260 mw, the design is still we ll wit hin the 300 mw specified at 230 vac. 0 50 10 0 15 0 20 0 25 0 30 0 35 0 80 10 0 1 2 0 1 4 0 1 60 1 8 0 2 00 2 2 0 2 4 0 26 0 2 80 ac i n p u t vo l t ag e (v ac ) i nput power (mw) figure 33 ? zero l oad in put powe r vs. input line voltage. page 32 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter 11.5 em i performance no change in c onduct ed emi per formance wa s meas ured. the r e su lts of the lnk520p and modified ep-16 were the s a me as the origin al ep-16 des ign, as shown in figures 24 and 25. howev e r, the optimiz ed switch ing charact e ristics of ln k520p produced a sign ificant reduction in radiated emi. figure 34 provi des a comparison of quasi-peak radiated emissions with the original ep-16 (lnk501 p) and modified ep-16 (lnk520p) designs . a 6 db figure 34 ? comp ari s o n of radiate d emissi on s, v in = 230 vac, 6 0 hz li ne, peak power poi n t. page 33 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 12 revision history date author revision description & chang es 2 1 - a u g - 0 2 p v 1 . 1 transformer symbol dots moved on the schematic (figure 5) 2 7 - a u g - 0 2 p v 1 . 2 capti on to figure 2 updated 14-jan-03 cw 1.3 transformer pin out error corrected (section 7.2) 2-apr-03 pv 1.4 updated to include opt ional component s 25-apr-03 am 1.5 r3 is replaced with r4 17-may-04 sh 1.6 added lnk520p in the high-side configuration (section 11) page 34 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
17-may-04 EPR-16 ? linkswitch 2.75 w c harger/adapter notes page 35 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m
EPR-16 - linkswitch 2.75 w charger/adapter 17-may-04 f o r t h e l a t e st u p d at es, vi si t o u r w e b sit e : w w w .pow e r i n t.c o m pow e r int e g r a t ions m a y m a k e c h a n g e s t o i t s prod uc ts a t a n y t i m e . p o w e r int e g r a t ions ha s no l i a b i l it y a r i s i n g f r o m y our us e o f a n y i n f o r m a t i on, de v i c e or c i rc ui t de s c ri be d he r e in nor d o e s it c o nv ey a n y l i c e n s e unde r i t s pa t e nt rig h t s or the r i g h ts of ot h er s . p o w e r in t e g r at io ns mak e s n o w a rr a n t i e s here i n a n d sp ecifica l ly d i scl a ims all wa rr a n t i es in cl u d in g , w i t h o u t l i m i tat i on , t h e imp l ie d wa rra n t i es of merch a n t abil i t y , fit n ess fo r a p a rt i c u l a r p u r p os e , a n d n o n - i n f r in g e me n t of t h ir d p a rty ri g h t s . p a te nt inf o rm a t ion t h e produc t s a n d a p pl ic a t io ns il l u s t ra t e d he re in ( i nc l u di ng c i r c uits e x t e rna l t o the pr od uc t s a nd tr a n s f orm e r c ons t r uc t i on) m a y be c o v e re d by one or m o re u . s. a nd f o re i g n pa t e nts or po te nt ia l l y by p e ndi ng u . s. a nd f o re i g n pa t e nt a p pli c a t i o ns a s s i g n e d t o p o w e r inte g r a t i ons . a c o m p l e te li s t of pow e r int e g r a t ions ? pa t e nts m a y be f ound a t www .po w e r i n t. c o m . th e p i lo go , tops wi tch , ti ny sw i t ch , li nk s w it c h , an d ec os mart ar e r e gist e r ed tr ad em ar ks o f p o w e r i n tegr ati o n s . pi expert an d dp a- sw i t c h a r e t r a d e m a r k s of p o w e r int e g r a t ions . ? c o py ri g h t 200 4, pow e r int e g r a t ions . po w e r integr ations world w ide s a le s supp ort loca t ions w o rl d he adq u art e rs 5 245 hel l ye r a v e n u e , san jos e , c a 9 513 8, usa m a i n : + 1 - 4 08 -414 -92 0 0 cu s t o m e r s e r v i c e : ph on e: + 1 - 4 08 -414 -96 6 5 f a x : + 1 - 4 08 -414 -97 6 5 e - m a i l : u s as al es @p ow er i n t . c o m g e rm an y rue c ke r t s t r a s s e 3, d - 80 33 6, m u ni c h , g e r m any ph on e: + 4 9 - 895 -52 7 - 3 910 f a x: + 4 9- 8 9 5 - 5 27- 3 9 2 0 e - m a i l : eu ro s a l e s@ p o w e ri n t .c o m ja p a n kei h in -t a t em on o 1 s t b l d g . 1 2 - 2 0 shin -yok oh a m a , 2- c h o m e , k o h o k u -k u, yok oham a -s h i , k a n a ga w a 2 2 2 - 003 3 , j a pa n ph o n e: + 8 1 - 45 -471 -10 2 1 f a x : + 8 1 - 45 -471 -37 1 7 e-m a il: j a pa ns al es @ p ow er i n t . c o m ta iw a n 5 f - 1 , no. 3 1 6 , nei hu rd . , se c . 1 nei hu d i s t . ta i p ei , tai w a n 1 1 4 , r . o . c . ph o n e: + 8 8 6 - 2 -265 9 - 4 5 70 f a x: + 8 8 6 - 2 - 2 6 59- 45 5 0 e-m a il: t a iw an s a le s @ p o wer i n t .c om chi n a (shanghai) rm 80 7 , p a c h e e r, co m m e rcial ce n t re , 55 5 n a n j i n g w e st ro ad , sh an gh ai , 200 041 , c h in a ph on e: + 8 6 - 21 -621 5 - 5 548 f a x : + 8 6 - 21 -621 5 - 2 468 e-m a il : c h i n asa l es @ p o w er in t. com in di a (t ec hn i c al suppor t ) i n n ovat e c h 26 1/a , g r o u n d f l oo r 7t h ma i n , 17 t h cro s s, s a das h iv an a g ar b a n g a l o r e 5 6 008 0 ph on e: + 9 1 - 80 -511 3 - 8 020 f a x: + 9 1- 8 0 - 5 1 13- 8 0 2 3 e- m a i l : i n di asa l es @ p o w er i n t. com kore a 8t h f l o o r , d o ng s u ng b l dg . 17 - 8 y o i d o - do ng , y o ung d e u ng po - g u, se ou l, 1 5 0 - 874 , k o rea ph o n e : +8 2-2 - 78 2 - 2 8 4 0 f a x: +8 2 - 2- 7 8 2- 4 4 2 7 e-m a il: k o r e as al es @p ow er i n t . c o m uk (e uro p e & a f ri ca he adquart e rs) 1 s t f l o o r, st. jam e s? s ho u s e eas t st r e e t fa r n h a m , su r r ey gu 9 7 t j un i t e d k i n g d o m p h o n e : + 4 4 - 1 2 5 2- 73 0- 1 4 0 f a x: + 4 4 - 1 2 5 2- 72 7- 6 8 9 e - m a i l : eu ro s a l e s@ p o w e r i n t . c o m chi n a ( s he nzhe n) r m # 170 5, b a o h u a b l d g . 1 016 h u a q i an g b e i l u , s h en zh en , g u a n gd o n g, 5 180 31 , ch i n a ph on e: + 8 6 - 755 -83 6 7 - 514 3 f a x: + 8 6 - 7 5 5 - 8 37 7- 9 6 10 e - m a i l : c h i n asa l es @ p o w er in t. com italy v i a vit t or i o ven e t o 1 2 , br e s s o m i l a n o , 2 009 1, i t a l y p h o n e : + 3 9- 0 2 8 - 9 28- 6 00 1 f a x: + 3 9- 0 2 8 - 9 28- 6 00 9 e - m a i l : eu ro s a l e s@ p o w e ri n t .c o m singapo r e 51 n e w t o n r o ad , #1 5- 0 8 / 1 0 g o l d hi l l p l az a, s i n g ap or e, 30 890 0 ph o n e: + 6 5 - 635 8 - 2 160 f a x : + 6 5 - 635 8 - 2 015 e-m a il: si nga po r e s a l e s @ po we rint . c o m a pplic ati o n s hotli ne w o r l d w i d e + 1 - 4 08 - 4 14 -966 0 a pplic ati o n s fa x w o r l d w i d e + 1 - 4 08 - 4 14 -976 0 page 36 of 36 po w e r integrati ons tel: +1 408 414 9660 fa x: +1 4 08 414 9760 www.po werint.co m

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