Title Reference Design Report for 1.6 W, Linear Replacement Adapter with 10 kV surge withstand Specification 85–265 VAC Input, 7.7 V, 210 mA Output Application Cordless Phone Adapter Author Power Integrations Applications Department Document Number RDR-83 Date Sept 29, 2006 Revision 1.0 Summary and Features • Highly efficient, low cost switching solution • Replacement for existing AC line transformer based design • Designed to withstand 10 kV common-mode surges • Ideal for applications connected to telephone network • EcoSmart® – meets all existing and proposed harmonized energy efficiency standards including: CECP (China), CEC, EPA, AGO, European Commission • No-load power consumption <220 mW at 265 VAC • 61.3% active-mode efficiency (exceeds requirement of 53.2%) • Integrated LinkSwitch safety/reliability features: • Accurate (± 5%), auto-recovering, hysteretic thermal shutdown function maintains safe PCB temperatures under all conditions • Auto-restart protects against output short circuits and open feedback loops • Meets EN55022 and CISPR-22 Class B conducted EMI with >15 dBµV margin • Meets IEC61000-4-5 Class 4 AC line surge 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. RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 Table Of Contents 1 2 Introduction.................................................................................................................3 Power Supply Specification ........................................................................................4 2.1 Typical Output Characteristic and limits ..............................................................5 3 Schematic...................................................................................................................6 4 Circuit Description ......................................................................................................7 4.1 Input Stage ..........................................................................................................7 4.2 LinkSwitch-LP......................................................................................................7 4.3 Feedback.............................................................................................................8 4.4 Output Rectification .............................................................................................9 5 PCB Layout ..............................................................................................................10 6 Bill Of Materials ........................................................................................................11 7 Transformer Specification.........................................................................................12 7.1 Electrical Diagram .............................................................................................12 7.2 Electrical Specifications.....................................................................................12 7.3 Materials............................................................................................................12 7.4 Transformer Build Diagram ...............................................................................13 7.5 Transformer Construction..................................................................................13 8 Design Spreadsheets ...............................................................................................14 9 Performance Data ....................................................................................................19 9.1 Efficiency ...........................................................................................................19 9.1.1 Active Mode ENERGY STAR / CEC Efficiency Measurement Data...........20 9.2 No-load Input Power..........................................................................................21 9.3 Available Standby Output Power.......................................................................21 9.4 Regulation .........................................................................................................22 9.4.1 VI Curve vs. Input Voltage..........................................................................22 10 Thermal Performance ...........................................................................................23 10.1 LNK562 Temperature Rise................................................................................23 10.2 Thermal Image ..................................................................................................23 11 Waveforms............................................................................................................24 11.1 Drain Voltage and Current, Normal Operation...................................................24 11.2 Output Voltage Start-up Profile..........................................................................24 11.3 Drain Voltage and Current Start-up Profile ........................................................25 11.4 Load Transient Response (50% to 100% Load Step) .......................................26 11.5 Output Ripple Measurements............................................................................27 11.5.1 Ripple Measurement Technique ................................................................27 11.5.2 Measurement Results ................................................................................28 12 Line Surge.............................................................................................................29 13 Conducted EMI .....................................................................................................30 14 Revision History ....................................................................................................32 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. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 1 Introduction This reference design report describes a switched-mode power supply that was designed to replace line frequency transformer based solutions. The supply uses a member of the LinkSwitch-LP family of devices, and is capable of withstanding common-mode line surges of up to 10 kV. That is often a requirement for applications that connect to a telephone line, such as modems, cordless phones and answering machines. The report includes the power supply specification, a circuit diagram, a bill of materials, transformer documentation, a printed circuit layout board, and performance data. Figure 1 – Populated Circuit Board Photograph. Page 3 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 2 Power Supply Specification Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power No Load Output Voltage Efficiency Full Load Required average efficiency at 25, 50, 75 and 100 % of POUT Symbol Min Typ Max Units Comment VIN fLINE 85 47 265 64 0.3 VAC Hz W 2 Wire – no P.E. 50/60 VOUT1 VRIPPLE1 IOUT1 6.7 7.7 8.7 400 0.21 0.21 V mV A POUT 1.4 1.6 11 20 MHz bandwidth W V η 60 % Measured at POUT 25 C ηCEC 53 % Per ENERGY STAR / CEC requirements o Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge Differential Mode Common Mode 2 6 Surge kV kV 10 2 Ambient Temperature TAMB 0 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com KV 50 o C 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω 100 kHz ring wave, 500 A short circuit current, differential Free convection, sea level Page 4 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 2.1 Typical Output Characteristic and Limits The following diagram shows the output characteristic of the LinkSwitch-LP solution and that of the linear transformer solution it was designed to replace. As can be seen, the LinkSwitch-LP solution provides a more controlled output characteristic. 18 115 VAC UPPER LIMIT LOWER LIMIT Linear Adapter RD-83 115 VAC 16 14 Volts 12 10 8 6 4 2 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Amps Figure 2 – Output Characteristic Comparison and Limits. Page 5 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 3 Schematic Figure 3 – Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 4 Circuit Description 4.1 Input Stage Components C1, C6, L1 and L3 comprise a balanced π filter. Resistor R5 dampens low frequency conducted EMI. The supply needs no Y1-type capacitor (that normally bridges the primary to secondary isolation barrier) due to U1’s frequency jitter function and the E-Shield™ techniques used in the design of transformer T1. This minimizes audible noise in applications connected to a phone line, by eliminating a path for line frequency leakage currents to pass onto the output of the supply. The supply easily meets EN55022B conducted EMI limits, with more than 15 dBµV of margin. A metal oxide varistor (RV1) and a wire wound resistor (RF1) attenuate differential line surges. The varistor is required to meet the 2 kV differential surge requirement. In applications where only 1 kV of surge immunity is required, RV1 can be eliminated. The wire wound resistor (RF1) must be able to withstand high transient dissipation from initial inrush current (when AC power is applied) and during line surges. 4.2 LinkSwitch-LP The LinkSwitch-LP family of ICs were designed to replace linear transformer solutions in low-power charger and adapter applications. Feedback to the LNK562P IC (U1) is derived from a resistor divider (R1 and R2) across the bias supply (D3 and C3), which lowers cost by eliminating the need for an optocoupler. Linear transformers typically use thermal fuses (over temperature cut-outs) for overload protection. However, once a thermal fuse trips, the entire charger or adapter must be thrown away, since thermal fuses cannot be reset or repaired. Latching thermal shutdown functions are typically used in ringing choke converter (RCC) based supplies. However, AC input power must be removed and reapplied to reset most thermal latches. Since customers typically don’t know this, they often return good units they thought were defective, simply because the thermal latch tripped and shut the unit off. The LinkSwitchLP family’s hysteretic thermal shutdown function has a very tight tolerance (142 °C, ±5%), and automatically restarts the power supply once the IC temperature drops below the lower temperature threshold. This maintains the average PCB temperature at a safe level under all conditions, and reduces the return rate of good units from the field. The auto-recovery feature also eliminates the noise sensitivity and component aging problems associated with discrete latching circuits. Pin 6 is eliminated from the IC package to extend the creepage distance between the DRAIN pin and all other low voltage pins; both at the package and on the PCB. This reduces the likelihood that tracking or arcing will occur due to moisture or board surface contamination (from dust and dirt), which improves reliability in high humidity and high pollution environments. During an output short circuit or an open loop condition, the LinkSwitch-LP’s auto-restart function limits output power to about 12% of the maximum. This protects both the load and the supply during prolonged overload conditions. Page 7 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 The LinkSwitch-LP family of ICs are self-biased, via a high-voltage current source that is internally connected to the DRAIN pin of the package. A capacitor (C2) connected to the BYPASS (BP) pin of the IC provides energy storage and local decoupling of the internal chip power. To further reduce no-load power consumption, a resistor can be used to provide operating current to the IC from the bias winding (once the power supply is operating). In this design, the bias winding voltage is about 14 V and the BP pin voltage is 5.8 V. Therefore, R6 (100 kΩ) provides about 80 µA of current to the BP pin. If the value of R6 were reduced, it could provide the entire 220 µA of IC supply current, which would further reduce the no-load power consumption of the supply. The worst-case, no-load power consumption of this supply is approximately 200 mW at an input voltage of 265 VAC, which is well below the maximum limit of most energy efficiency standards. Heat generation is also kept to a minimum in this design, given the high operating efficiency at all line and load conditions. 4.3 Feedback The output voltage of the supply is regulated based on feedback from the primary-side bias supply. The bias winding voltage is rectified and filtered by D3 and C3. The leakage inductance between the output winding and the bias winding induces error in the bias winding voltage. Using a standard rectifier diode for D3 makes the bias winding voltage more accurately track the output voltage. Resistor R7 preloads (3 mA) the output of the bias supply, which further reduces the error and also limits the no-load output voltage. A resistor divider (R1 and R2) provides the feedback voltage to the FB pin of U1. The values of R1 and R2 are selected so that when the output voltage is at the desired nominal value, the voltage on the FB pin is 1.69 V, and about 70 µA flows into the FB pin. The LinkSwitch-LP family of devices use ON/OFF control to regulate the output of the supply. During constant voltage (CV) operation, switching cycles are skipped when the current into the FB pin exceeds 70 µA. As the load on the output of the supply reduces, more switching cycles are skipped. As the load increases, fewer cycles are skipped. The result is that the average or effective switching frequency varies with the load. This makes the efficiency fairly consistent over the entire load range, since the switching losses scale with the load on the output of the supply. When the load on the output of the supply reaches its maximum power capability, no switching cycles are skipped. If the load is increased beyond that point, the output voltage of the supply will start to drop. As the output voltage drops, the voltage on the FB pin also drops, and the IC linearly reduces its switching frequency. This keeps the output current from increasing significantly. Once the FB pin voltage falls below 0.8 V for more than 100 ms, all LinkSwitch-LP devices enter an auto-restart mode. While in auto-restart, the controller enables MOSFET switching for 100 ms. If the FB pin voltage does not exceed 0.8 V during the 100 ms, the controller disables MOSFET switching. MOSFET switching is alternately enabled and disables at a duty cycle of about 12% until the fault condition clears. This protects both the supply and the load. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 4.4 Output Rectification The transformer secondary winding is rectified by D4 and filtered by C4. A small preload resistor (R8) limits the no-load output voltage. Decreasing the value of the preload resistor will further reduce the no-load output voltage, at the expense of increasing the no-load input power consumption. In this design, a fast diode (rather than an ultra-fast) was used for D4 to lower cost and EMI emissions. Page 9 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 5 PCB Layout During a common mode surge, the specified surge voltage appears across the isolation barrier. Elimination of the optocoupler and Y1-type capacitor in the design allowed the necessary PCB clearance and creepage distance to be obtained, so that the supply can withstand a 10 kV surge without resorting to expensive, special components. To increase the creepage and clearance, the standard triple insulated wire used for the secondary winding was terminated as flying leads that were soldered directly into the PCB, instead of being terminated to transformer bobbin pins. A 0.185 inch long, 4.7 mm wide slot was placed along the isolation barrier. Additionally, the primary and secondary traces are separated by 0.4 inches (10 mm). A spark gap was added across the isolation barrier (marked as points (B) in Figure 4), so that any arcing that might occur would take place at a designated point with a well defined path. On the primary side of the isolation barrier, the spark gap trace returns directly to C6, which keeps surge currents away from the low-voltage pins of U1. Two additional spark gaps were placed across L1 and L3, to prevent the breakdown of insulation on those parts. Note: During 10 kV common mode surge testing, no arcing occurred across any of the spark gaps. (A) (B) (B) Figure 4 – RD83 Printed Circuit Layout (2.175” x 1.475” / 55.25 mm x 37.47 mm). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 6 Bill Of Materials 1 Ref Description Des 2 C1, C6 3.3 µF, 400 V, Electrolytic, (8 x 11.5) 2 1 C2 100 nF, 50 V, Ceramic, Z5U Panasonic ECU-S1H104MEA 3 1 C3 10 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) Nippon Chemi-Con EKMG500ELL100ME11D 4 1 C4 5 1 D1 Nippon Chemi-Con 100 µF, 25 V, Electrolytic, Low ESR, 250 mΩ, (6.3 x 11.5) 600 V, 1 A, Fast Recovery Diode, 200 ns, DO-41 Vishay 6 2 D2, D3 600 V, 1 A, Rectifier, DO-41 Vishay 1N4005 7 1 D4 50 V, 1 A, Fast Recovery, 200 ns, DO-41 Vishay 1N4933 8 2 J1, J2 Test Point, WHT, THRU-HOLE MOUNT Keystone 5012 9 1 J3 Output cord, 6 ft, 22 AWG, 0.25 Ω, 2.1 mm connector Generic 10 2 J4, J5 PCB Terminal Hole, 22 AWG N/A N/A 11 2 L1, L3 1 mH, 0.15 A, Ferrite Core Tokin SBCP-47HY102B 12 1 R1 22.1 kΩ, 1%, 1/4 W, Metal Film Yageo MFR-25FBF-22K1 13 1 R2 3.01 kΩ, 1%, 1/4 W, Metal Film Yageo MFR-25FBF-3K01 14 Yageo CFR-25JB-4K7 15 3 R5, R7, 4.7 kΩ, 5%, 1/4 W, Carbon Film R8 1 R6 100 kΩ, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-100K 16 1 RF1 10 Ω, 2.5 W, Fusible/Flame Proof Wire Wound Vitrohm CRF253-4 10R 17 1 RV1 275 V, 23 J, 7 mm, RADIAL Littlefuse V275LA4 Custom Transformer Core: EE16, See Power Integration's document EPR-83 for Transformer Specification Hical Magnetics SIL6043 CWS EP-83 Santronics SNX1388 Bobbin: Horizontal Extended Creepage 5+5 pin Taiwan Shulin TF-1613 www.bobbin.com.tw LinkSwitch-LP, LNK562P, DIP-8B Power Integrations Item Qty 18 19 1 1 T1 U1 Manufacturer Manufacturer Part # Nippon Chemi-Con ESMQ401ELL3R3MHB5D ELXZ250ELL101MFB5D 1N4937 LNK562P Note: For reduced line frequency ripple at 85 VAC, increase the values of C1 and C6 to 4.7 µF. Page 11 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 7 Transformer Specification 7.1 Electrical Diagram FL 3 Bias/Core Cancellation 29T #37AWG X 2 1 LAYER 4 2 WD #4 Secondary 17T #30AWG TIW FL Primary 176T #37AWG 3 LAYERS Shield WD #3 15T #32 AWG X 2 WD #1 WD #2 1 NC 1 Figure 5 –Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 1 second, 60 Hz, from Pins 1-4 to Flying leads 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 flying leads shorted, measured at 100 kHz, 0.4 VRMS 6000 VAC 3.5 mH, ±10% 250 kHz (Min.) 115 µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: PC40EE16-Z, TDK or equivalent gapped for AL of 114 nH/T2. Gap approx. 0.2 mm. Bobbin: EE16 Horizontal 10 pin Taiwan Shulin TF-1613 or equivalent Magnet Wire: #37 AWG Magnet Wire: #32 AWG Triple Insulated Wire: #30 AWG Tape, 3M 1298 Polyester Film, 2.0 Mils thick, 8 mm wide Varnish Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 36 29-Sept-06 7.4 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Transformer Build Diagram Tape WD #4 Secondary FLYING LEAD FLYING LEAD (MARKED) Tape Pin 1 Pin 1 NC Tape WD #3 Shield WD #2 Primary Pin 2 Pin 3 Pin 4 Tape WD #1 Cancellation Figure 6 – Transformer Build Diagram. 7.5 Transformer Construction Bobbin orientation is such that primary pins are on the left hand side of the winding spindle WD1 Cancellation and Bias Winding Primary pin side of the bobbin oriented to the left hand side. Temporarily start at pin 7. Wind 29 bifilar turns of item [3] from right to left. Wind with tight tension evenly across the bobbin. Terminate finish on pin 4. Take the end of the winding that was started on pin 7 and terminate it on pin 3. Insulation 1 Layer of tape [6] for insulation. WD #2 Primary Winding Insulation WD #3 Shield Winding Start at Pin 2. Wind 58 turns of item [3] from left to right. Then wind 59 turns on the next layer from right to left. Wind 59 turns from left to right on the third layer. Wind with tight tension evenly across the bobbin. Bring the wire across the bobbin and terminate the finish on pin 1. Use one layer of tape [6] for basic insulation. Temporarily start at Pin 7. Wind 15 bifilar turns of item [4]. Wind from right to left with tight tension across the entire bobbin width. Terminate on pin 1. Cut the wire from Pin 7 and leave it unconnected. Core Assembly and trim flying leads Use three layers of tape [6] for basic insulation. Temporarily start at Pin 7 (allow 1” of wire at the start for the flying lead). Wind 17 turns of item [5] from right to left with tight tension. Allow 1” of wire at the finish for the flying lead, at the right side of bobbin. Remove the start from pin 7 and mark. Exit start at right hand side of the bobbin. Wrap windings with three layers of tape [6]. Gap core such that the inductance between pins 1 & 2 is 3.5 mH ±10%. The gap is approximately 0.2 mm. Assemble and secure the core halves. Trim flying leads to 0.65”±0.05”. Tin leads 0.15”±0.05”. Cut bobbin pins 5,6,7 and 8. Varnish Dip varnish assembly with item [7]. Insulation WD #4 Secondary Winding Outer insulation Gap Core Page 13 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 8 Design Spreadsheets ACDC_LinkSwitchLP_053106; Rev.1.12; Copyright Power Integrations 2006 INPUT INFO OUTPUT UNIT ENTER APPLICATION VARIABLES ACDC_LinkSwitch-LP_053106_Rev1-12.xls; LinkSwitch-LP Continuous/Discontinuous Flyback Transformer Design Spreadsheet RDR-83 VACMIN 85 Volts Minimum AC Input Voltage VACMAX 265 Volts Maximum AC Input Voltage fL 50 Hertz AC Mains Frequency VO 7.70 Volts IO 0.21 Amps Output Voltage (main) measured at the end of output cable (For CV/CC designs enter typical CV tolerance limit) Power Supply Output Current (For CV/CC designs enter typical CC tolerance limit) Choose "YES" from the 'CV/CC output' drop down box at the top of this spreadsheet for approximate CV/CC output. Choose "NO" for CV only output Enter the resistance of the output cable (if used) Constant Voltage / Constant Current Output YES Output Cable Resistance CVCC Volts 0.25 0.25 Ohms PO 1.63 Watts Feedback Type BIAS Bias Winding Add Bias Winding YES Yes Clampless design YES Clample ss n 0.65 0.65 Z 0.35 0.35 tC 2.90 CIN 9.40 Input Rectification Type Loss Allocation Factor (Secondary side losses / Total losses) mSeconds Bridge Rectifier Conduction Time Estimate UFarads H Output Power (VO x IO + dissipation in output cable) Choose 'BIAS' for Bias winding feedback and 'OPTO' for Optocoupler feedback from the 'Feedback Type' drop down box at the top of this spreadsheet Choose 'YES' in the 'Bias Winding' drop down box at the top of this spreadsheet to add a Bias winding. Choose 'NO' to continue design without a Bias winding. Addition of Bias winding can lower no load consumption Choose 'YES' from the 'clampless Design' drop down box at the top of this spreadsheet for a clampless design. Choose 'NO' to add an external clamp circuit. Clampless design lowers the total cost of the power supply Efficiency Estimate at output terminals. For CV only designs enter 0.7 if no better data available H Input Capacitance Choose H for Half Wave Rectifier and F for Full Wave Rectification from the 'Rectification' drop down box at the top of this spreadsheet ENTER LinkSwitch-LP VARIABLES LinkSwitch-LP Chosen Device ILIMITMIN LinkSwitch-LP device LNK562 LNK562 0.124 Amps Minimum Current Limit ILIMITMAX 0.146 Amps Maximum Current Limit fSmin 61000 Hertz Minimum Device Switching Frequency Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand I^2fMIN 1099 A^2Hz I^2fTYP 1221 A^2Hz VOR 90.00 90 Volts Reflected Output Voltage 10 Volts LinkSwitch-LP on-state Drain to Source Voltage 0.90 0.9 Volts Output Winding Diode Forward Voltage Drop VDS VD I^2f Minimum value (product of current limit squared and frequency is trimmed for tighter tolerance) I^2f typical value (product of current limit squared and frequency is trimmed for tighter tolerance) KP 1.99 Ripple to Peak Current Ratio (0.9<KRP<1.0 : 1.0<KDP<6.0) ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE16 EE16 P/N: PC40EE16-Z EE16_B OBBIN P/N: EE16_BOBBIN Core Bobbin User-Selected transformer core EE16 AE 0.192 cm^2 LE 3.5 cm AL Core Effective Cross Sectional Area Core Effective Path Length 1140 nH/T^2 BW Ungapped Core Effective Inductance 8.6 mm M Bobbin Physical Winding Width 0 mm L Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of primary layers 2 NS 17 Number of Secondary Turns NB 44 Number of Bias winding turns VB 22.26 Volts Bias Winding Voltage R1 37.47 k-ohms R2 3.00 k-ohms Resistor divider component between bias wiinding and FB pin of LinkSwitch-LP Resistor divider component between FB pin of LinkSwitch-LP and primary RTN Place this diode on the return leg of the bias winding for optimal EMI. See LinkSwitch-LP Design guide for more information Recommended Bias Diode 1N4003 DC INPUT VOLTAGE PARAMETERS VMIN 73 Volts Minimum DC Input Voltage VMAX 375 Volts Maximum DC Input Voltage DMAX 0.45 Maximum Duty Cycle IAVG 0.04 Amps Average Primary Current CURRENT WAVEFORM SHAPE PARAMETERS IP 0.12 Amps Minimum Peak Primary Current IR 0.12 Amps Primary Ripple Current IRMS 0.05 Amps Primary RMS Current TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP_TOLERANCE Page 15 of 36 3486 uHenries 10 % Typical Primary Inductance. +/- 10% Primary inductance tolerance Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 NP 178 Primary Winding Number of Turns ALG 110 nH/T^2 Gapped Core Effective Inductance BM 1490 Gauss ur 1654 Maximum Operating Flux Density, BM<1500 is recommended AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core BAC 745 Gauss LG 0.20 Mm Gap Length (Lg > 0.1 mm) BWE 17.2 Mm Effective Bobbin Width OD 0.10 Mm INS 0.02 Mm DIA 0.07 Mm Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter AWG 41 AWG CM 8 Cmils CMA Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils 150 Cmils/Amp Primary Winding Current Capacity (150 < CMA < 500) TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP 1.30 Amps Peak Secondary Current ISRMS 0.47 Amps Secondary RMS Current IRIPPLE 0.42 Amps Output Capacitor RMS Ripple Current CMS 93 Cmils AWGS 30 AWG DIAS 0.26 Mm ODS 0.51 Mm INSS 0.12 Mm Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness VOLTAGE STRESS PARAMETERS VDRAIN - Volts PIVS 44 Volts Peak Drain Voltage is highly dependent on Transformer capacitance and leakage inductance. Please verify this on the bench and ensure that it is below 650 V to allow 50 V margin for transformer variation. Output Rectifier Maximum Peak Inverse Voltage TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 7.7 Volts IO1 0.211 Amps PO1 1.63 Watts VD1 0.9 Volts NS1 17.00 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Main Output Voltage (if unused, defaults to single output design) Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Page 16 of 36 29-Sept-06 ISRMS1 IRIPPLE1 PIVS1 Recommended Diodes Pre-Load Resistor RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 0.470 Amps 0.42 Amps 44 Volts SB160, 11DQ06 Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Recommended Diodes for this output 3 k-Ohms CMS1 94 Cmils AWGS1 30 AWG DIAS1 0.26 mm ODS1 0.51 mm Recommended value of pre-load resistor Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire 2nd output VO2 Volts Output Voltage IO2 Amps Output DC Current PO2 0.00 Watts VD2 0.7 Volts NS2 ISRMS2 IRIPPLE2 PIVS2 1.38 Output Winding Number of Turns 0.000 Amps 0.00 Amps Output Winding RMS Current Output Capacitor RMS Ripple Current 3 Volts Output Rectifier Maximum Peak Inverse Voltage 0 Cmils Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Recommended Diode CMS2 Output Power Output Diode Forward Voltage Drop Recommended Diodes for this output AWGS2 AWG DIAS2 mm ODS2 mm Maximum Outside Diameter for Triple Insulated Wire 3rd output VO3 Volts Output Voltage IO3 Amps Output DC Current PO3 0.00 Watts VD3 0.7 Volts NS3 ISRMS3 IRIPPLE3 PIVS3 1.38 Output Winding Number of Turns 0.000 Amps 0.00 Amps Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage 0 Cmils Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Recommended Diodes for this output AWGS3 AWG DIAS3 mm ODS3 mm Page 17 of 36 Output Winding RMS Current 3 Volts Recommended Diode CMS3 Output Power Output Diode Forward Voltage Drop Maximum Outside Diameter for Triple Insulated Wire Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 Total power 1.63 Watts Total Output Power Negative Output N/A If negative output exists enter Output number; eg: If VO2 is negative output, enter 2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency 90 Efficiency (%) 80 70 60 50 40 30 50 75 100 125 150 175 200 225 250 275 300 AC Input Voltage (V) Figure 7 – Efficiency vs. Input Voltage, Room Temperature, 60 Hz. Page 19 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 9.1.1 Active Mode ENERGY STAR / CEC Efficiency Measurement Data All single output cordless phone adapters manufactured for sale in California after July 1st, 2007 must meet the CEC requirement for minimum active mode efficiency and no-load input power. Cordless phone adapters must also meet this specification on a voluntary basis to be able to display the ENERGY STAR logo. Minimum active mode efficiency is defined as the average efficiency of 25, 50, 75 and 100% of rated output power, based on the nameplate output power: ENERGY STAR / CEC Active Mode Efficiency Specification Nameplate Output (PO) Minimum Efficiency in Active Mode of Operation <1W ≥ 1 W to ≤ 49 W > 49 W 0.49 × PO 0.09 × ln (PO) + 0.49 [ln = natural log] 0.84 x PO For adapters that are single input voltage only, the measurement is made at the rated, single nominal input voltage (115 VAC or 230 VAC). For universal input adapters, the measurement for ENERGY STAR qualification is made at both nominal input voltages (115 VAC and 230 VAC); for CEC qualification, measurements are made at 115 VAC only. To meet the standard, the measured average efficiency (or efficiencies for universal input supplies) must be greater than or equal to the efficiency specified by the CEC / ENERGY STAR standard. Percent of Full Load 25 50 75 100 Average CEC specified minimum average efficiency (%) Efficiency (%) 115 VAC 230 VAC 61.0 65.4 66.5 67.4 65.1 56.1 62.6 63.6 62.9 61.3 53.2 More states within the USA and other countries are adopting this standard. For the latest information, please visit the PI Green Room at: http://www.powerint.com/greenroom/regulations.htm Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 36 29-Sept-06 9.2 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand No-load Input Power The supply easily meets the ENERGY STAR / CEC and European no-load power consumption specifications of 0.5 W and 0.3 W (respectively). 0.3 Input Power (W) 0.25 0.2 0.15 0.1 0.05 0 0 50 100 150 200 250 300 AC Input Voltage (V) Figure 8 – No Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. 9.3 Available Standby Output Power The supply provides >500 mW of available output power, at an input power of 1 W. 1 0.9 Available Output Power (W) 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 50 100 150 200 250 300 AC Input Voltage (V) Figure 9 – Available Output Power at 1 Watt Input Power vs. Input Voltage. Page 21 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 9.4 29-Sept-06 Regulation 9.4.1 VI Curve vs. Input Voltage 12 LOWER LIMIT UPPER LIMIT 115 VAC 85 VAC 230 VAC 265 VAC Output Voltage (V) 10 8 6 4 2 0 0 0.1 0.2 0.3 0.4 0.5 Output Current (A) 0.6 0.7 0.8 Figure 10 – Output VI Curve, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 10 Thermal Performance 10.1 LNK562 Temperature Rise The RD-83 was installed within a sealed plastic enclosure, placed inside a sealed cardboard box, and placed into a thermal chamber at 50 °C. The cardboard box prevented the chamber circulation fan from blowing air across the plastic enclosure. A thermocouple, attached to pin 2 of U1, was used to monitor its temperature. Item Temperature (°C) 85 VAC 265 VAC Ambient 50 50 LinkSwitch (U1) 78 84 This result indicates acceptable thermal margin of approximately of 16 °C to the recommended maximum SOURCE pin temperature of 100 °C 10.2 Thermal Image An infrared thermograph of the board was taken to measure the temperature of other components. This identified U1 and D4 as the highest temperature components. Using the results from the previous section, this indicates that D4 would also have an acceptable temperature rise at 50 °C ambient. Figure 11 – Thermal Image of the RD-83 at Full Load, 85 VAC Input and Ambient Temperature of 22 °C. Page 23 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 11 Waveforms 11.1 Drain Voltage and Current, Normal Operation Figure 12 – 85 VAC, Full Load . Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V/Div, 2 µs / div. Figure 13 – 265 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V/Div, 2 µs / div. 11.2 Output Voltage Start-up Profile The output was loaded with a 39 Ω resistive load. Figure 14 – Start-up Profile, 115VAC. 2 V, 20 ms / div. Figure 15 – Start-up Profile, 230 VAC. 2 V, 20 ms / div. The start-up waveforms show minimal output overshoot (<200 mV). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 11.3 Drain Voltage and Current Start-up Profile The output was loaded with a 39 Ω resistive load and the output profile captured. These waveforms show no sign of core saturation and acceptable margin to the recommended maximum drain voltage of 650 VPK. Figure 16 – 85 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V & 1 ms / div. Page 25 of 36 Figure 17 – 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V & 1 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 11.4 Load Transient Response (50% to 100% Load Step) In the figures shown below, signal averaging was used to better enable viewing the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response. Figure 18 – Transient Response, 115 VAC, 50-10050% Load Step. Top: Load Current, 0.1 A/div. Bottom: Output Voltage 200 mV, 500 µs / div. Figure 19 – Transient Response, 230 VAC, 50-10050% Load Step. Upper: Load Current, 0.1 A/ div. Bottom: Output Voltage 200 mV, 500 uS / div. These results were significantly lower than the linear adapter where ripple and transient response variation was greater than 1 VP-P. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 11.5 Output Ripple Measurements 11.5.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce the pickup of spurious signals. Details of the probe modification are provided in Figure 20 and Figure 21. The 5125BA probe adapter (from probe master) 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 Figure 21). Probe Ground Probe Tip Figure 20 – Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed). Figure 21 – Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added). Page 27 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 11.5.2 Measurement Results Figure 22 – Ripple, 85 VAC, Full Load. 5 ms, 50 mV / div (240 mVP-P). Figure 23 – Ripple, 115 VAC, Full Load. 5 ms, 50 mV / div (80 mVP-P). Figure 24 – Ripple, 230 VAC, Full Load. 5 ms, 50 mV /div (130mVP-P). Figure 25 – Ripple of a Linear adaptor, 115 VAC Input, Full Load. 2 ms, 200 mV/div (800 mVP-P). Figure 22 shows increased line frequency ripple. If required, this could be lowered to the level shown in Figure 23 by increasing the value of C6 and C1 to 4.7 µF. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 12 Line Surge Differential and common mode 1.2/50 µs surge testing was completed on a single test unit, to IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. The output of the supply was loaded to full load, and correct operation was verified following each surge event. Surge Level (V) +2000 -2000 +10000 -10000 Input Voltage (VAC) 230 230 230 230 Injection Location Injection Phase (°) Test Result (Pass/Fail) L to N L to N L,N to RTN L,N to RTN 90 90 90 90 Pass Pass Pass Pass Unit passed under all test conditions. Page 29 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 13 Conducted EMI Measurements were made with the output RTN of the supply connected to the artificial hand connection on the LISN (line impedance stabilization network) to represent worstcase conditions. The results show excellent margin of >15 dBµV to both the quasi-peak and the average limit lines. Power Integrations 28.Aug 06 09:43 Att 10 dB AUTO dBµV 80 70 1 QP CLRWR EN55022Q 2 AV CLRWR EN55022A RBW 9 kHz MT 500 ms PREAMP OFF 1 MHz LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG Marker 1 [T1 ] 28.50 dBµV 182.849162999 kHz 10 MHz SGL 60 50 TDF 40 1 30 20 10 0 -10 -20 150 kHz 30 MHz Figure 26 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Power Integrations 28.Aug 06 09:53 Att 10 dB AUTO dBµV 80 70 1 QP CLRWR EN55022Q 2 AV CLRWR EN55022A RBW 9 kHz MT 500 ms PREAMP OFF 1 MHz LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG Marker 1 [T1 ] 28.76 dBµV 182.849162999 kHz 10 MHz SGL 60 50 TDF 40 1 30 20 10 0 -10 -20 150 kHz 30 MHz Figure 27 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits. Page 31 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 14 Revision History Date 29-Sept-06 Author JAC Revision 1.0 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Description & changes Initial Release Reviewed PV, JJ, DA Page 32 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Notes Page 33 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 Notes Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Notes Page 35 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 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 NON-INFRINGEMENT 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, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2006 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] GERMANY Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3910 Fax: +49-89-5527-3920 e-mail: [email protected] JAPAN Keihin Tatemono 1st Bldg 2-12-20 Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa ken, Japan 222-0033 Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN 5F, No. 318, Nei Hu Rd., Sec. 1 Nei Hu Dist. Taipei, Taiwan 114, R.O.C. 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