CCG2 20W Design Example Report.pdf

Design Example Report
Title
20 W USB PD Power Supply Using Cypress
CCG2 CYPD2134 and InnoSwitchTM-CP
INN2215K
Specification
85 VAC – 264 VAC Input;
5 V 3 A; 9 V, 2.2 A Outputs
Application
Mobile Phone Charger
Author
Applications Engineering Department
Document
Number
DER-533
Date
February 23, 2016
Revision
1.2
Summary and Features
 InnoSwitch-CP industry first AC/DC IC with isolated, safety rated integrated feedback
 USB-PD compliance via single secondary side IC (CCG2 CYPD2134)
 All the benefits of secondary-side control with the simplicity of primary-side regulation
 Insensitive to transformer variation
 Built in synchronous rectification for high efficiency
 Meets DOE6 and CoC V5 2016

<30 mW no-load input power integrated thermal protection
Primary sensed overvoltage protection

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>.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
Table of Contents
1 2 3 4 Introduction ...................................................................................................... 4 Power Supply Specification ................................................................................. 5 Schematic ......................................................................................................... 6 Circuit Description .............................................................................................. 7 4.1 Input EMI Filtering....................................................................................... 7 4.2 InnoSwitch-CP IC Primary ............................................................................ 7 4.3 InnoSwitch-CP IC Secondary ........................................................................ 8 4.4 USB Type-C and PD Interface ....................................................................... 9 5 PCB Layout ...................................................................................................... 10 6 Bill of Materials ................................................................................................ 11 7 Transformer Specification ................................................................................. 13 7.1 Electrical Diagram ...................................................................................... 13 7.2 Electrical Specifications .............................................................................. 13 7.3 Material List .............................................................................................. 13 7.4 Transformer Build Diagram......................................................................... 14 7.5 Transformer Construction ........................................................................... 14 7.6 Winding Illustrations .................................................................................. 15 8 Common Mode Choke Specifications .................................................................. 20 8.1 90 H Common Mode Choke (L1) ............................................................... 20 8.1.1 Electrical Diagram ............................................................................... 20 8.1.2 Electrical Specifications ........................................................................ 20 8.1.3 Material List ........................................................................................ 20 8.1.4 Illustrations ........................................................................................ 20 8.2 10 mH Common Mode Choke (L3) .............................................................. 21 8.2.1 Electrical Diagram ............................................................................... 21 8.2.2 Electrical Specifications ........................................................................ 21 8.2.3 Materials List ...................................................................................... 21 8.2.4 Winding Instructions ........................................................................... 21 8.2.5 Illustrations ........................................................................................ 21 9 Transformer Design Spreadsheet ....................................................................... 22 10 Performance Data ......................................................................................... 25 10.1 Efficiency vs. Load (at the End of 100 m Resistor) ..................................... 26 10.2 No-Load Input Power at 5 VOUT ................................................................... 28 10.3 Average Efficiency (at the End of 100 m Resistor)...................................... 29 10.3.1 Average Efficiency Requirements .......................................................... 29 10.4 Average Efficiency and 10% Load at 115 VAC Input ..................................... 30 10.4.1 5.0 V Out ........................................................................................... 30 10.4.2 9.0 V Out ........................................................................................... 30 10.5 Average Efficiency at 230 VAC Input and 10% Load ..................................... 30 10.5.1 5.0 V Out ........................................................................................... 30 10.5.2 9.0 V Out ........................................................................................... 30 10.6 Line and Load Regulation ........................................................................... 31 Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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Page 2 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
10.6.1 Line Regulation (at USB Socket) ........................................................... 31 10.6.2 Load Regulation (at USB Socket) .......................................................... 32 10.7 CV/CC vs. Line (at the USB Socket) ............................................................. 34 11 Thermal Performance in Open Case at 9 V / 2.2 A Output ................................ 36 11.1 85 VAC Input ............................................................................................ 36 11.2 115 VAC Input ........................................................................................... 36 11.3 230 VAC Input ........................................................................................... 37 11.4 265 VAC Input ........................................................................................... 37 12 Waveforms ................................................................................................... 38 12.1 Load Transient Response (at the End of the Cable) ...................................... 38 12.2 Switching Waveforms ................................................................................. 39 12.2.1 Drain Voltage and Current ................................................................... 39 12.2.2 Drain Voltage and Current Start-up ....................................................... 40 12.2.3 SR FET Voltage ................................................................................... 40 12.2.4 Output Voltage and Current Start-up (at End of the Cable) ..................... 41 12.3 Output Voltage Change (Measured at the End of the Cable) .......................... 42 12.3.1 Output Voltage Change (USB-PD) ......................................................... 42 12.4 Output Ripple Measurements ...................................................................... 43 12.4.1 Ripple Measurement Technique ............................................................ 43 12.4.2 Ripple Amplitude vs. Line ..................................................................... 44 13 Conducted EMI ............................................................................................. 47 13.1 Floating Output (PK / AV) ........................................................................... 47 13.1.1 5 V, 3 A .............................................................................................. 47 13.1.2 9 V, 2.2 A ........................................................................................... 48 13.2 Artificial Hand Ground (PK / AV).................................................................. 49 13.2.1 5 V, 3 A .............................................................................................. 49 13.2.2 9 V, 2.2 A ........................................................................................... 50 13.3 Earth Ground (PK / AV) .............................................................................. 51 13.3.1 5 V, 3 A .............................................................................................. 51 13.3.2 9 V, 2.2 A ........................................................................................... 52 14 Revision History ............................................................................................ 53 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.
Page 3 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
1 Introduction
This document is an engineering report describing a 5 V / 3.0 A or 9 V / 2.2 A output USB
Type-C and USB-PD charger using the InnoSwitch-CP and Cypress CCG2 USB Type-C
USB-PD Controller. This design shows the high power density and efficiency that is
possible due to the high level of integration of the InnoSwitch-CP controller providing
exceptional performance.
This document contains the power supply specification, schematic, bill of materials,
transformer documentation, printed circuit layout, and performance data
Figure 1 – Populated Circuit Board Photograph, Top.
Figure 2 – Populated Circuit Board Photograph, Bottom.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page 4 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
2 Power Supply Specification
The table below represents the minimum acceptable performance of the design. Actual
performance is listed in the results section.
Description
Input
Voltage
Frequency
No-load Input Power (230 VAC)
5 V Output
Output Voltage
Symbol
Min
VIN
fLINE
85
47
Output Ripple Voltage
VRIPPLE1
Output Current
9 V Output
Output Voltage
Output Ripple Voltage
VOUT1
IOUT1
Continuous Output Power
Conducted EMI
POUT
264
64
28
VAC
Hz
mW
V
150
mV
3.3
A
9
V
150
mV
A
20
Comment
2 Wire – no P.E.
Measured at 230 VAC.
3%
At the end of cable. Cable needs to
have a resistance of 100mΩ.
20 MHz bandwidth.
5%
At the end of cable. Cable needs to
have a resistance of 100 mΩ.
At the end of cable. Cable needs to
have a resistance of 100 mΩ.
W
Meets CISPR22B / EN55022B
Designed to meet IEC60950 /
UL1950 Class II
Safety
Ambient Temperature
3.0
VRIPPLE1
IOUT1
50/60
25
Max Units
5
VOUT1
Output Current
Typ
TAMB
0
40
o
C
Free convection, sea level.
Note: To use this design for a charger/adapter, circuit board would need to be modified
depending on shape and form factor of the housing. ESD and Line surge performance
should be evaluated and layout adjusted to meet the target specification.
Page 5 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
3 Schematic
Figure 3 – Schematic.
Power Integrations, Inc.
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Page 6 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
4 Circuit Description
4.1 Input EMI Filtering
Fuse F1 isolates the circuit and provides protection from component failure, and the
common mode choke L1 with capacitor C8 provides attenuation for EMI. Bridge rectifier
BR1 rectifies the AC line voltage and provides a full wave rectified DC across the filter
consisting of C2, L3, and C3. The inductor L3 and capacitors C2, C3 form a pi-filter. This
filter provides differential and common mode noise filtering. Thermistor RT1 limits the
inrush current when the power supply is connected to the input AC supply.
4.2 InnoSwitch-CP IC Primary
One end of the transformer primary is connected to the rectified DC bus; the other is
connected to the drain terminal of the MOSFET inside the InnoSwitch-CP IC (U1).
A low cost RCD clamp formed by diode D1, resistors R1 and R2, and capacitor C4 limits
the peak drain voltage of U1 at the instant of turn off of the MOSFET inside U1. The
clamp helps to dissipate the energy stored in the leakage reactance of transformer T1.
The IC is self-starting, using an internal high-voltage current source to charge the BPP
pin capacitor (C7) when AC is first applied. During normal operation the primary side
block is powered from an auxiliary winding on the transformer T1. Output of the auxiliary
(or bias) winding is rectified using diode D2 and filtered using capacitor C6. Resistor R4
limits the current being supplied to the BPP pin of the InnoSwitch-CP IC (U1). A linear
regulator comprising of resistor R3, BJT Q1 and Zener diode VR1 prevent any change in
current through R4. The RC network comprising of resistor R5 and capacitor C5 offer
damping to the high frequency ringing in the voltage across diode D2 which reduces
radiated EMI.
Output regulation is achieved using On/Off control, the number of enabled switching
cycles are adjusted based on the output load. At high load, most switching cycles are
enabled, and at light load or no-load most cycled are disabled or skipped. Once a cycle is
enabled, the MOSFET will remain on until the primary current ramps to the device
current limit for the specific operating state. There are four operating states (current
limits) arranged such that the frequency content of the primary current switching pattern
remains out of the audible range until at light load where the transformer flux density
and therefore audible noise generation is at a very low level.
Zener diode VR3 offers primary sensed output over voltage protection. In a flyback
converter, output of the auxiliary winding tracks the output voltage of the converter. In
case of over voltage at output of the converter, the auxiliary winding voltage increases
and causes breakdown of VR3 which then causes a current to flow into the BPP pin of
InnoSwitch-CP IC U1. If the current flowing into the BPP pin increases above the ISD
Page 7 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
threshold which has a nominal value of 7.6 mA, the InnoSwitch-CP controller will latch
off and prevent any further increase in output voltage.
4.3 InnoSwitch-CP IC Secondary
The secondary side of the InnoSwitch-CP IC provides output voltage, output current
sensing and drive to a MOSFET providing synchronous rectification. The secondary of the
transformer is rectified by MOSFET Q2 and filtered by capacitors C10 and C11. High
frequency ringing during switching transients that would otherwise create radiated EMI is
reduced via a RC snubber, R6 and C9.
The gate of Q2 is turned on by secondary side controller inside IC U1, based on the
winding voltage sensed via resistor R10 and fed into the FWD pin of the IC.
In continuous conduction mode of operation, the MOSFET is turned off just prior to the
secondary side commanding a new switching cycle from the primary. In discontinuous
mode of operation, the power MOSFET is turned off when the voltage drop across the
MOSFET falls below a threshold of approximately 24 mV. Secondary side control of the
primary side power MOSFET avoids any possibility of cross conduction of the two
MOSFETs and provides extremely reliable synchronous rectification.
The secondary side of the IC is self-powered from either the secondary winding forward
voltage or the output voltage. Capacitor C13 connected to the BPS pin of InnoSwitch-CP
IC U1 provides decoupling for the internal circuitry.
During CC operation, when the output voltage falls, the device will power itself from the
secondary winding directly. During the on-time of the primary side power MOSFET, the
forward voltage that appears across the secondary winding is used to charge the
decoupling capacitor C13 via resistor R10 and an internal regulator. This allows output
current regulation to be maintained down to ~3.0 V. Below this level the unit enters
auto-restart until the output load is reduced.
Output current is sensed by monitoring the voltage drop across resistor R12 between the
IS and GND pins with a threshold of approximately 50 mV to reduce losses. Once the
internal current sense threshold is exceeded the device adjusts the number of switch
pulses to maintain a fixed output current.
Below the CC threshold, the device operates in constant voltage mode. Output voltage is
regulated so as to achieve a voltage of 1.2 V on the FB pin. Resistor R9 and capacitor
C12 form a phase lead network that ensure stable operation and minimize output voltage
overshoot and undershoot during transient load conditions. Capacitor C14 provides noise
filtering of the signal at the FB pin.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page 8 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
4.4 USB Type-C and PD Interface
In this design, CCG2 CYPD2134-24QXIT (U3) is the USB Type-C and PD controller.
Output of the InnoSwitch-CP powers the CCG2 device using a 3.3 V linear regulator U4.
Resistors R8 and R11 forms the feedback divider network to sense the output of
Innoswitch. Output voltage is changed to 9 V when sink requests for the same. To
change the output to 9V, pin-14 of IC U3 goes low and adds resistor R15 in parallel to
the bottom resistor of the feedback divider network.
USB-PD protocol is communicated over either CC1 or CC2 line depending on the
orientation in which type-C plug is connected.
P-MOSFETS Q10 and Q11 make the USB Type-C receptacle cold socket when no device is
attached to the charger as per the USB Type-C specification. VBUS_OUT is discharged via
resistor R34 by turning on the MOSFET Q13.
Page 9 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
5 PCB Layout
PCB copper thickness is 2.0 oz.
Figure 4 – Printed Circuit Layout, Top.
Figure 5 – Printed Circuit Layout, Bottom.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page 10 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
6 Bill of Materials
Item
1
2
Qty
1
1
Ref Des
BR1
C2
Description
600 V, 1 A, Bridge Rectifier, SMD, DFS
10 F, 400 V, Electrolytic, (8 x 12)
Mfg Part Number
DF06S-E3/45
ERK2GM100F12OT
3
1
C3
33 F, 400 V, Electrolytic, (12.5 x 20)
KMG401ELL330MK20S
4
5
6
7
8
9
10
11
12
13
14
15
1
1
1
1
1
1
2
2
1
1
1
2
16
3
17
18
19
2
1
1
C4
C5
C6
C7
C8
C9
C10 C11
C12 C14
C13
C15
C16
C17 C29
C18 C19
C30
C21 C22
D1
D2
20
1
F1
21
22
23
24
1
2
1
1
FL1
FL2 FL3
J1
J4
330 pF 16 V, Ceramic, X7R, 0402
600 V, 1 A, Rectifier, Glass Passivated, POWERDI123
200 V, 1 A, Rectifier, Glass Passivated, POWERDI123
FUSE, 1.25A 250VAC, Slow, 8.35 mm x 4.0 mm x 7.7
mm
Flying Lead, Hole size 30 mils
Flying Lead, Hole size 70 mils
CONN, AC Recept Panel, R/A, PCB pins
Connector, USB TYPE C, R/A, Receptacle
25
1
L1
Custom, 108 H, constructed on Core 35T0375-10H
26
1
L3
16.6 mH, xA, Ferite Toroid, 4 Pin, Output
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Q1
Q2
Q10 Q11
Q12 Q13
R1
R2
R3
R4
R5
R6
R8
R9
R10
R11
R12
R15
R21
R23
R24
R25
R29
R30
Page 11 of 54
2.2 nF, 630 V, Ceramic, X7R, 1206
56 pF, 250 V, Ceramic, NPO, 0603
22 uF, 50 V, Electrolytic, (5 x 11)
100 nF, 25 V, Ceramic, X7R, 0805
100 pF, 250 VAC, Film, X1Y1
1 nF, 200 V, Ceramic, X7R, 0805
470 F, 16 V, Al Organic Polymer, 12 m, (8 x 11.5)
1000 pF, 100 V, Ceramic, NPO, 0603
2.2 F, 25 V, Ceramic, X7R, 0805
1 f 35 V, Ceramic, X7R, 0603
2.2 F, 10 V, Ceramic, X7R, 0603
100 nF 16 V, Ceramic, X7R, 0402
1 F 16 V, Ceramic, X5R, 0402
NPN, Small Signal BJT, 40 V, 0.2 A, SOT-323
100 V, 40 A, N-Channel, PowerPAK SO-8
30 V, 100 A, P-Channel, TDSON-8
MOSFET, N-CH, 30V, 300MA, SOT-323
RES, 430 k, 5%, 1/4 W, Thick Film, 1206
RES, 51 , 5%, 1/4 W, Thick Film, 1206
RES, 100 k, 5%, 1/10 W, Thick Film, 0603
RES, 3.57 k, 1%, 1/16 W, Thick Film, 0603
RES, 100 , 5%, 1/10 W, Thick Film, 0603
RES, 5.6 , 5%, 1/8 W, Thick Film, 0805
RES, 100 k, 1%, 1/16 W, Thick Film, 0603
RES, 1 k, 5%, 1/10 W, Thick Film, 0603
RES, 47 , 5%, 1/10 W, Thick Film, 0603
RES, 34 k, 1%, 1/16 W, Thick Film, 0603
RES, 0.015 , 0.5 W, 1%, 0805
RES, 30.9 k, 1%, 1/10 W, Thick Film, 0402
RES, 22 , 5%, 1/10 W, Thick Film, 0603
RES, 0 , 5%, 1/8 W, Thick Film, 0805
RES, 4.70 M, 1%, 1/4 W, Thick Film, 1206
RES, 3.30 M, 1%, 1/4 W, Thick Film, 1206
RES, 49.9 k, 1%, 1/10 W, Thick Film, 0402
RES, 1.00 k, 1%, 1/8 W, Thick Film, 0805
C3216X7R2J222K
GQM1875C2E560JB12D
UPW1H220MDD
08053C104KAT2A
DE1B3KX101KB4BN01F
08052C102KAT2A
RNE1C471MDN1
C1608C0G2A102J
C2012X7R1E225M
C1608X7R1V105M
GRM188R71A225KE15D
L05B104KO5NNNC
Mfg
Vishay
Aishi
Nippon ChemiCon
TDK
Murata
Nichicon
AVX
TDK
AVX
Nichicon
TDK
TDK
TDK
Murata
Samsung
C1005X5R1C105M
TDK
C0402C331K4RACTU
DFLR1600-7
DFLR1200-7
Kemet
Diodes, Inc.
Diodes, Inc.
RST 1.25-BULK
Bel Fuse
N/A
N/A
770W-X2/10
DX07S024XJ1R1100
N/A
N/A
Qualtek
JAE Electronics
Power
Integrations
Power
Integrations
Diodes, Inc.
Vishay
Infineon
Rohm Semi
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Rohm Semi
Rohm Semi
Panasonic
Panasonic
MMST3904-7-F
SIR876ADP-T1-GE3
BSC030P03NS3 G
RJU003N03T106
ERJ-8GEYJ434V
ERJ-8GEYJ510V
ERJ-3GEYJ104V
ERJ-3EKF3571V
ERJ-3GEYJ101V
ERJ-6GEYJ5R6V
ERJ-3EKF1003V
ERJ-3GEYJ102V
ERJ-3GEYJ470V
ERJ-3EKF3402V
ERJ-6BWFR015V
ERJ-2RKF3092X
ERJ-3GEYJ220V
ERJ-6GEY0R00V
KTR18EZPF4704
KTR18EZPF3304
ERJ-2RKF4992X
ERJ-6ENF1001V
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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DER-533 20 W USB-PD InnoSwitch-CP Charger
49
50
51
52
53
54
55
56
1
2
1
1
1
1
1
1
R31
R32 R40
R34
R37
R38
R41
RT1
T1
57
1
U1
58
59
60
61
1
1
1
1
U3
U4
VR1
VR3
RES, 10 , 1%, 1/10 W, Thick Film, 0402
RES, 100.0 k, 1%, 1/10 W, Thick Film, 0402
RES, 200 , 1%, 1/4 W, Thick Film, 1206
RES, 4.7 k, 5%, 1/10 W, Thick Film, 0402
RES, 100 , 5%, 1/10 W, Thick Film, 0402
RES, 10.0 k, 1%, 1/10 W, Thick Film, 0402
NTC Thermistor, 5 , 1 A
Bobbin, RM8, Vertical, 12 pins
InnoSwitch-CP, Off-Line CV/CC Flyback Switcher,
ReSOP-16B
IC, USB Type-C Port Controller
IC, REG, LDO, 3.3V, 0.3A, SOT23-3
10 V, 5%, 150 mW, SSMINI-2
24 V, 5%, 150 mW, SSMINI-2
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
23-Feb-16
ERJ-2RKF10R0X
ERJ-2RKF1003X
ERJ-8ENF2000V
ERJ-2GEJ472X
ERJ-2GEJ101X
ERJ-2RKF1002X
MF72-005D5
RM8/12/1
INN2215K
CYPD2134-24LQXIT
P2210N-3.3TRG1
DZ2S100M0L
DZ2S240M0L
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Cantherm
Schwartzpunkt
Power
Integrations
Cypress Semi
Diodes, Inc.
Panasonic
Panasonic
Page 12 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
7 Transformer Specification
7.1
Electrical Diagram
FL2
2
WD1 (Primary) 39T ‐ #26AWG
WD4 (Secondary): 4T – 2 x #21AWG_TIW
FL1
NC
WD3 (Shield): 9T – 2x#28AWG
FL3
10
WD2 (Bias): 8 T – 2 x #26 AWG
NC
11
Figure 6 – Transformer Electrical Diagram.
7.2
Electrical Specifications
Electrical Strength
Primary Inductance
Resonant
Frequency
Primary Leakage
Inductance
7.3
1 second, 60 Hz, from pins 2, 10, 12, and FL4 to FL1/FL2.
Pin 2 – FL3, all other windings open, measured at 100
kHz, 0.4 VRMS.
Pin 2 – FL3, all other windings open.
Pin 2 – FL3, with pins FL1/FL2 shorted, measured at
100kHz, 0.4 VRMS.
3000 VAC
612 H, 5%
1100 kHz (Min.)
16 H (Max.)
Material List
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
Description
Core: TDK PC95 RM08-Z ,PI # 99-00022-00, or equivalent, gapped for ALG of 392 nH/t2.
Bobbin: RM8-12pins(6/6), Ferroxcube-CSV-RM8-1S-12P-G, PI#: 25-01022-00; or equivalent.
Clip: RM8, Allstar Magnetic, CLI/P-RM8/I.
Magnet Wire: #26 AWG, solderable double coated.
Magnet Wire: #28 AWG, solderable double coated.
Magnet Wire: #21 AWG, Triple Insulated Wire.
Tape: Polyester Film, 3M 1350-1, 9.0 mm wide.
Varnish.
Page 13 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
7.4
23-Feb-16
Transformer Build Diagram
WD4 (Secondary): 4T – 2 x #21AWG_TIW
FL3
FL2
WD3 (Shield): 9T – 2 X # 28 AWG
NC
WD2 (Bias): 8 T – 2 x #26 AWG
11
10
WD1 (Primary) 39T ‐ #26AWG
NC
FL1
2
Figure 7 – Transformer Build Diagram.
7.5
Transformer Construction
Bobbin Preparation
WD1
Primary Winding
Insulation
WD2
Bias Winding
Insulation
WD3
Shield
Insulation
WD4
Secondary Winding
Insulation
Final Assembly
For the purpose of these instructions, bobbin is oriented on winder such that pin
side is on the left side.
Winding direction is clockwise direction.
Start at pin 2. Wind 39 turns of item [4] in approximately 2 layers. Finish as
marked FL1.
Use 1 layer of item [7] for insulation.
Starting at pin 10, wind 8 bifilar turns of item [5]. Spread turns evenly across
bobbin. Finish at pin 11.
Use 1 layer of item [7] for insulation.
Temporarily hang wire item [5] on pin 1 or 2, for start lead, wind 9 bifilar turns
of item [5], and spread turns evenly across bobbin. At the last turn cut wire for
no-connect, and also cut start lead for no-connect.
Use 4 layers of item [7] for insulation.
Take two parallel strands of item [6]. Mark start end as FL2, wind 4 turns of
item [6], and finish as FL3.
Use 2 layers of item [7] to secure the windings.
Insert cores, gapped for inductance specified. Secure core halves using clips item
[3].
Cut short pins: 1, 3, 4, 5, 6, 7, 8, and 9.
Dip varnish item [8].
Power Integrations, Inc.
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Page 14 of 54
23-Feb-16
7.6
DER-533 20 W USB-PD InnoSwitch-CP Charger
Winding Illustrations
Bobbin Preparation
For the purpose of these
instructions, bobbin is
oriented on winder such
that pin side is on the left
side.
Winding direction is
clockwise direction.
WD1
Primary winding
Start at pin 2. Wind 39
turns of item [4] with tight
tension in 2 layers. Finish
as marked FL1.
Page 15 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
FL1
Insulation
Use 1 layer of item [7] for
insulation.
WD2
Bias winding
Starting at pin 10, wind 8
bifilar turns of item [4].
Spread turns evenly across
bobbin. Finish at pin 11.
Power Integrations, Inc.
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Page 16 of 54
23-Feb-16
Insulation
WD3
Shield
Page 17 of 54
DER-533 20 W USB-PD InnoSwitch-CP Charger
Use 1 layer of item [7] for
insulation.
Temporarily hang wire item
[5] on pin 1 or 2, for start
lead, wind 9 bifilar turns of
item [5], and spread turns
evenly across bobbin.
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
Cut short for No-Connect
At the last turn cut wire for
no-connect, and also cut
start lead for no-connect.
Use 4 layers of item [7] for
insulation.
Insulation
FL2
WD4
Secondary winding
Power Integrations, Inc.
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Take two parallel strands of
item [6]. Mark start end as
FL2, wind 4 turns of item
[6], and finish as FL3.
Page 18 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
FL2
FL3
FL2
Use 2 layers of item [7] to
secure the windings.
Insulation
FL3
Insert cores, gapped for
inductance specified.
Secure core halves using
clips item [3].
Cut short pins: 1, 3, 4, 5, 6,
7, 8, and 9.
Dip varnish item [8].
Final Assembly
FL2
FL3
FL1
Page 19 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
8 Common Mode Choke Specifications
8.1
90 H Common Mode Choke (L1)
8.1.1 Electrical Diagram
Figure 8 –Inductor Electrical Diagram.
8.1.2 Electrical Specifications
Inductance
Primary Leakage Inductance
Pins 1-2 measured at 100 kHz, 0.4 RMS.
Pins 1-2, with 3-4 shorted.
108 H ±20%
0.5 H
8.1.3 Material List
Item
[1]
[2]
[3]
Description
Toroid: FERRITE INDUCTR TOROID .415" O.D.;Mfg Part number: 35T0375-10H.
Dim: 9.53 mm O.D. x 4.75 mm I.D. x 3.18 mm L.
Magnet Wire: #29 AWG.
Triple Insulated Wire #29 AWG.
8.1.4 Illustrations
Top View
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Front View
Page 20 of 54
23-Feb-16
8.2
DER-533 20 W USB-PD InnoSwitch-CP Charger
10 mH Common Mode Choke (L3)
8.2.1 Electrical Diagram
1
55T
#31 AWG 2
55T
#31 AWG
4
3
Figure 9 – Inductor Electrical Diagram.
8.2.2 Electrical Specifications
Inductance
Core effective
Inductance
Primary Leakage
Inductance
Pins 1-4 and pins 2-3 measured at 100 kHz, 0.4 RMS.
16.6 mH ±25%
5500 nH/N2
80 H
Pins 1-4, with 2-3 shorted.
8.2.3 Materials List
Item
[1]
[2]
Description
Toroid: FERRITE INDUCTR TOROID T14 x 8 x 5.5.
PI Part number: #32-00286-00.
Divider -- Fish paper, insulating cotton rag, 0.010” thick, PI #: 66-00042-00.
Cut to size 8 mm x 5.5 mm.
Magnet Wire: #31 AWG Heavy Nyleze
8.2.4 Winding Instructions
 Use 4 ft of item [2], start at pin 1 wind 55 turns end at pin 4.
 Do the same for another half of Toroid, start at pin 2 and end at pin 3.
8.2.5 Illustrations
Side View
Page 21 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
9 Transformer Design Spreadsheet
ACDC_InnoSwitchCP_021616;
Rev.1.1; Copyright
INPUT
Power Integrations
2016
ENTER APPLICATION VARIABLES
INFO
OUTPUT
UNIT
VACMIN
85
V
VACMAX
fL
265
50
V
Hz
VO_1
9.00
9.39
V
IO_1
2.14
2.14
A
20.08
W
Power_1
Info
n_1
0.85
0.85
Z_1
0.50
0.50
VO_2
5.00
5.30
V
IO_2
3.00
3.00
A
15.90
W
Power_2
n_2
0.80
0.80
Z_2
0.50
0.50
VO_3
IO_3
Power_3
n_3
0.80
Z_3
0.50
VO_4
IO_4
Power_4
n_4
0.80
Z_4
0.50
tC
3.00
CIN
43.00
Enclosure
Adapter
Cable compensation
Potential
type
Divider
ENTER InnoSwitch-RC VARIABLES
InnoSwitch-RC
Auto
Cable drop
6%
compensation
Complete Part
Number
Chose Configuration
ILIMITMIN
ILIMITTYP
ILIMITMAX
fSmin
STD
0.00
0.00
0.00
0.80
0.50
0.00
0.00
0.00
0.80
0.50
3.00
43.00
Adapter
Potential
Divider
V
A
W
V
A
W
mS
uF
INN2215
Select Cable Drop Compensation option.
INN2215K
Final part number including package
Standard Current Limit
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Minimum AC Input Voltage. Universal=85VAC to
155VAC. High-Line=185VAC to 215VAC
Maximum AC Input Voltage
AC line frequency
Desired output voltage at the end of cable for
configuration 1
Output current for configuration 1
Specified output power exceeds the device's
capability. Increase device size or verify performance
on bench
Efficiency Estimate at output terminals for
configuration 1. Use 0.8 if no better data available
Ratio of secondary side losses to the total losses in
the power supply for configuration 1. Use 0.5 if no
better data available
Desired output voltage at the end of cable for
configuration 2
Power Supply Output Current (corresponding to peak
power) for configuration 2
Continuous Output Power, including cable drop
compensation for configuration 2
Efficiency Estimate at output terminals for
configuration 2. Use 0.8 if no better data available
Ratio of secondary side losses to the total losses in
the power supply for configuration 2. Use 0.5 if no
better data available
Configuration 3 is turned off
Configuration 3 is turned off
Configuration 3 is turned off
Configuration 3 is turned off
Configuration 3 is turned off
Configuration 4 is turned off
Configuration 4 is turned off
Configuration 4 is turned off
Configuration 4 is turned off
Configuration 4 is turned off
Bridge Rectifier Conduction Time Estimate
Input capacitor
Select between Adapter and Open Frame
The output voltage is varied by varying the lower
feedback resistor
Recommended InnoSwitch-CP
6%
0.893
0.950
1.007
93000
InnoSwitch-CP Continuous/Discontinuous
Flyback Transformer Design Spreadsheet
A
A
A
Hz
Enter "RED" for reduced current limit, "STD" for
standard current limit or "INC" for increased current
limit
Minimum Current Limit
Typical Current Limit
Maximum Current Limit
Minimum Device Switching Frequency
Page 22 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
78.52
I^2fmin
VOR
VDS
88
5.00
88
5.00
KP
0.435
KP_TRANSIENT
0.289
A^2kHz
V
V
Worst case I2f for power delivery
Reflected output voltage assigned to configuration 1
InnoSwitch on-state Drain to Source Voltage
Minimum Value of KP given all configurations and i2f
conditions
Minimum Value of KP_TRANSIENT given all
configurations and i2f conditions
ENTER BIAS WINDING VARIABLES
VB
10.00
V
VDB
0.70
V
NB
8.00
V
119.63
V
PIVB
ENTER TRANSFORMER CORE VARIABLES
Core Type
RM8
Core
Bobbin
AE
LE
AL
BW
RM8
PC47RM8Z-12
BRM8-718CPFR
0.64
cm^2
3.80
cm
1950
nH/T^2
9.05
mm
M
0.00
LAYERS_PRIMARY
2
NS
4
4
DC INPUT VOLTAGE PARAMETERS
VMIN
79
VMAX
375
PRIMARY CURRENT WAVEFORM SHAPE PARAMETERS
mm
V
V
DMAX
0.543
IP_AVG
0.294
A
IP_PEAK
1.014
A
IP_RMS
0.532
A
IP_RIPPLE
0.745
A
612
uHenry
5.0
39
402
%
nH/T^2
BM
2610
Gauss
BAC
867
Gauss
ur
LG
BWE
OD
921
0.16
18.1
0.46
mm
mm
mm
INS
0.06
mm
DIA
0.40
mm
Minimum bias winding voltage. Bias voltage will be
higher for higher output voltages. Verify
performance on the bench.
Bias Winding Diode Forward Voltage Drop
Minimum bias winding number of turns to ensure the
minimum bias winding voltage.
Minimum PIV rating of the bias diode given all
configurations and i2f conditions.
Enter Transformer Core
Enter core part number, if necessary
Enter bobbin part number, if necessary
Core Effective Cross Sectional Area
Core Effective Path Length
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
Safety Margin Width (Half the Primary to Secondary
Creepage Distance)
Number of Primary Layers
Number of Secondary Turns
Minimum DC Input Voltage
Maximum DC Input Voltage
Maximum value of DMAX given all configurations and
i2f conditions
Maximum value of the average primary current given
all configurations and i2f conditions
Maximum value of the peak primary current given all
configurations and i2f conditions
Maximum value of the primary RMS current given all
configurations and i2f conditions
Maximum value of the primary ripple current given
all configurations and i2f conditions
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP
LP_TOLERANCE
NP
ALG
Page 23 of 54
5.0
Typical Primary Inductance. +/- 10% to ensure a
minimum primary inductance of 532 uH
Primary inductance tolerance
Primary Winding Number of Turns
Gapped Core Effective Inductance
Maximum operating flux density given all
configurations and i2f conditions
Maximum AC Flux Density for Core Loss Curves (0.5
X Peak to Peak) given all configurations and i2f
conditions
Relative Permeability of Ungapped Core
Gap Length (Lg > 0.1 mm)
Effective Bobbin Width
Maximum Primary Wire Diameter including insulation
Estimated Total Insulation Thickness (= 2 * film
thickness)
Bare conductor diameter
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
AWGP
27
AWG
CMP
203
CMAP
382
Cmils
Cmils/Am
p
A/mm^2
CDP
5.2
SECONDARY CURRENT WAVEFORM SHAPE PARAMETERS
IS_PEAK
9.818
A
IS_RMS
6.007
A
IS_RIPPLE
5.204
A
TRANSFORMER SECONDARY DESIGN PARAMETERS
NS
4
CMS
1201
Cmils
Cmils/Am
p
CMAS
200
CDS
9.2
A/mm^2
AWGS
19
AWG
DIAS
ODS
SECONDARY SR FET DESIGN PARAMETERS
SRFET
Auto
RDSON_HOT
PIV_rated
0.91
2.26
mm
mm
Si7456
0.0420
100
Ohms
V
VD
0.098
V
PD
1.545
W
VOLTAGE STRESS PARAMETERS
VDRAIN
570
V
PIVS
63
V
DESIGN CONFIGURATION PARAMETERS
Configuration
1
1
VO
9.00
V
IO
2.14
A
PO
20.08
W
n
Z
DMAX
VOR
KP
KP_transient
IPP
IPRMS
IPRIPPLE
0.85
0.50
0.543
87.8
0.733
0.520
1.01
0.53
0.74
ISP
9.82
A
ISRMS
4.77
A
ISRIPPLE
4.26
A
Power Integrations, Inc.
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V
A
A
A
Primary Wire Gauge (Rounded to next smaller
standard AWG value)
Bare conductor effective area in circular mils
Primary wire circular mils per amp
Primary wire current density
Maximum value of the peak secondary current, given
all configurations and i2f conditions
Maximum value of the secondary RMS current, given
all configurations and i2f conditions
Maximum value of the output capacitor RMS ripple
current, given all configurations and i2f conditions
Number of secondary turns
Secondary Bare Conductor minimum circular mils
Worst-case cecondary wire circular mils per amp
given all configurations and i2f conditions
Worst-case secondary wire current density given all
configurations and i2f conditions
Worst-case secondary wire gauge (Rounded up to
next larger standard AWG value) given all
configurations and i2f conditions
Minimum Bare Conductor Diameter
Maximum Outside Diameter for Triple Insulated Wire
Recommended SR FET for the design
RDSon at 100C
Rated voltage of selected SR FET
Output Synchronous Rectification FET Forward
Voltage Drop
Output Synchronous Rectification FET Power
Dissipation
Maximum Drain Voltage Estimate
Output Rectifier Maximum Peak Inverse Voltage,
assuming the primary has a Voltage spike 40%
above VMAX and VO*1.05
Select the configuration number
Output voltage at the end of the cable for the
selected configuration
Output current for the selected configuration
Output power at the end of the cable for the
selected configuration
Efficiency for the selected configuration
Loss allocation factor for the selected configuration
DMAX for the selected configuration
VOR for the desired configuration
KP for the selected configuration
KP_transient for the selected configuration
Primary switch peak current given all i2f conditions
Primary switch RMS current given all i2f conditions
Primary switch current ripple given all i2f conditions
Secondary switch peak current given all i2f
conditions
Secondary switch RMS current given all i2f conditions
Secondary switch curent ripple given all i2f
conditions
Page 24 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
10 Performance Data
Note: Connector mechanical tolerances in the USB Type-C connectors from certain
manufactures have been found to have a loose fit which either does not allow the
connector on the cable to mate with the connector on the board or causes intermittent
connections. Full Load Efficiency vs. Line (at the end of 100 m Resistor)
90
5V
9V
Efficiency (%)
88
86
84
82
80
78
80
100
120
140
160
180
200
220
240
260
Input Voltage (VAC)
Figure 10 – Efficiency vs. Line Voltage, Room Temperature.
Page 25 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
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10.1 Efficiency vs. Load (at the End of 100 m Resistor)
100
5V
9V
95
Efficiency (%)
90
85
80
75
70
65
60
0
10
20
30
40
50
60
70
80
90
100
Output Power (%)
Figure 11 – Efficiency vs. Load, Room Ambient. 115 VAC.
Power Integrations, Inc.
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Page 26 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
120
5V
9V
110
Efficiency (%)
100
90
80
70
60
50
40
0
10
20
30
40
50
60
70
80
90
Output Power (%)
Figure 12 – Efficiency vs. Load, Room Ambient. 230 VAC.
Page 27 of 54
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100
DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
10.2 No-Load Input Power at 5 VOUT
40
Input Power (mW)
35
30
25
20
15
10
5
80
100
120
140
160
180
200
220
240
260
280
Input Voltage (VAC)
Figure 13 – No-Load Input Power vs. Input Line Voltage, Room Temperature.
Power Integrations, Inc.
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Page 28 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
10.3 Average Efficiency (at the End of 100 m Resistor)
10.3.1 Average Efficiency Requirements
Test
>6 V
Voltage
2016
CoC v5
Tier 2
10%
Load
>6 V
Voltage
Now
CoC v5
Tier 1
10%
Load
>6 V
Voltage
2016
CoC v5
Tier 2
83.4%
86.0%
73.4%
76.0%
Average
Average
Average
<6 V
Voltage
Now
Energy
Star 2
<6 V
Voltage
2016
New
IESA2007
<6 V
Voltage
Now
CoC v5
Tier 1
<6 V
Voltage
2016
CoC v5
Tier 2
10%
Load
<6 V
Voltage
Now
CoC v5
Tier 1
10%
Load
<6 V
Voltage
2016
CoC v5
Tier 2
77.2 %
81.4%
79.0%
81.8%
69.5%
72.5%
Average
Average
Average
Average
>6 V
Voltage
Now
Energy
Star 2
>6 V
Voltage
2016
New
IESA2007
>6 V
Voltage
Now
CoC v5
Tier 1
Required
Efficiency
81.8 %
85.5%
Test
Average
Model
Effective
Regulation
Model
Effective
Regulation
Required
Efficiency
Page 29 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
10.4 Average Efficiency and 10% Load at 115 VAC Input
10.4.1 5.0 V Out
% Load
100%
75%
50%
25%
10%
POUT
(W)
14.71
11.18
7.48
3.75
1.5
Efficiency
(%)
81.72
83.98
85.61
86.62
84.94
Average Efficiency
(%)
POUT
(W)
20.26
15.17
10.11
5.03
1.75
Efficiency
(%)
86.8
87.69
88.36
88.11
83.00
Average Efficiency
(%)
84.48
10.4.2 9.0 V Out
% Load
100%
75%
50%
25%
10%
87.74
10.5 Average Efficiency at 230 VAC Input and 10% Load
10.5.1 5.0 V Out
% Load
100%
75%
50%
25%
10%
POUT
(W)
14.76
11.20
7.50
3.75
1.93
Efficiency
(%)
82.36
84.14
85.54
85.599
83.79
Average Efficiency
(%)
POUT
(W)
20.34
15.26
10.12
5.03
1.75
Efficiency
(%)
87.14
87.85
88.28
86.48
81.14
Average Efficiency
(%)
84.41
10.5.2 9.0 V Out
% Load
100%
75%
50%
25%
10%
Power Integrations, Inc.
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87.44
Page 30 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
10.6 Line and Load Regulation
10.6.1 Line Regulation (at USB Socket)
14
5V
9V
Output Voltage (V)
12
10
8
6
4
2
0
80
100
120
140
160
180
200
220
240
260
Input Voltage (VAC)
Figure 14 – Output Voltage vs. Input Line Voltage, Room Temperature.
Page 31 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
10.6.2 Load Regulation (at USB Socket)
14
5V
9V
Output Voltage (V)
12
115 VAC Input
10
8
6
4
2
0
0
10
20
30
40
50
60
70
80
90
100
Output Power (%)
Figure 15 – Output Voltage vs. Output Load, Room Temperature. 115 VAC.
Power Integrations, Inc.
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Page 32 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
14
5V
9V
Output Voltage (V)
12
230 VAC Input
10
8
6
4
2
0
0
10
20
30
40
50
60
70
80
90
Output Power (%)
Figure 16 – Output Voltage vs. Output Load, Room Temperature. 230 VAC.
Page 33 of 54
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
10.7 CV/CC vs. Line (at the USB Socket)
7
85 VAC
115 VAC
230 VAC
265 VAC
6
Output Voltage (V)
5 V Output
5
4
3
2
1
0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Output Current (A)
Figure 17 – Output Voltage vs. Output Current, Room Temperature. 5 V Output.
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Page 34 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
12
85 VAC
115 VAC
230 VAC
265 VAC
Output Voltage (V)
10
8
6
4
2
0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Output Current (A)
Figure 18 – Output Voltage vs. Output Current, Room Temperature. 9 V Output.
Page 35 of 54
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3.5
DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
11 Thermal Performance in Open Case at 9 V / 2.2 A Output
11.1 85 VAC Input
Figure 19 – Transformer Side.
Ambient = 26.2 ºC.
Transformer, T1 = 66.4 ºC.
SR-FET Top, Q2 = 65.5 ºC.
Thermistor, RT1 = 80.1 ºC.
Figure 20 – InnoSwitch-CP Side.
Ambient = 26.2 ºC.
InnoSwitch-CP, U1 = 72.5 ºC.
SR FET, Q2 = 66.9 ºC.
Bridge Rectifier, BR1 = 61.8 ºC.
11.2 115 VAC Input
Figure 21 – Transformer Side.
Ambient = 26.2 ºC.
Transformer, T1 = 64.7 ºC.
SR-FET Top, Q2 = 64.0 ºC.
Thermistor, RT1 = 71.8 ºC.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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Figure 22 – InnoSwitch-CP Side.
Ambient = 26.2 ºC.
InnoSwitch-CP, U1 = 68.3 ºC.
SR FET, Q2 = 65.6 ºC.
Bridge Rectifier, BR1 = 53.2 ºC.
Page 36 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
11.3 230 VAC Input
Figure 23 – Transformer Side.
Ambient = 26.2 ºC.
Transformer, T1 = 65.8 ºC.
SR-FET Top, Q2 = 65.8 ºC.
Thermistor, RT1 = 59.8 ºC.
Figure 24 – InnoSwitch-CP Side.
Ambient = 26.2 ºC.
InnoSwitch-CP, U1 = 72.1 ºC.
SR FET, Q2 = 68.7 ºC.
Bridge Rectifier, BR1 = 42.8 ºC.
11.4 265 VAC Input
Figure 25 – Transformer Side.
Ambient = 26.2 ºC.
Transformer, T1 = 68.2 ºC.
SR-FET Top, Q2 = 67.9 ºC.
Thermistor, RT1 = 58.8 ºC.
Page 37 of 54
Figure 26 – InnoSwitch-CP Side.
Ambient = 26.2 ºC.
InnoSwitch-CP, U1 = 73.7 ºC.
SR FET, Q2 = 69.4 ºC.
Bridge Rectifier BR1 = 41.6 ºC.
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
12 Waveforms
12.1 Load Transient Response (at the End of the Cable)
Note: This test demonstrates change of output voltage from 5 V to 9 V and from 9 V to 5
V with a load of 2.2 A connected at the output of the charger. A USB-PD host board from
Cypress Semiconductor [CY4504 Rev 05] was used for the test
Figure 27 – Transient Response.
85VAC, 5.0 V, 0 - 3 A Load Step.
VMIN 4.54 V, VMAX: 5.07 V.
Upper: VOUT, 0.5 V / div., 100 ms / div.
Lower: ILOAD, 1 A / div.
Figure 28 – Transient Response.
265VAC, 5.0 V, 0 - 3 A Load Step.
VMIN 4.59 V, VMAX: 5.07 V.
Upper: VOUT, 0.5 V / div., 100 ms / div.
Lower: ILOAD, 1 A / div.
Figure 29 – Transient Response.
85 VAC, 9 V, 0 – 2.2 A Load Step.
VMIN: 8.80 V, VMAX: 9.25 V.
Upper: VOUT, .5 V / div., 100 ms / div.
Lower: ILOAD, 1 A / div.
Figure 30 – Transient Response.
265 VAC, 9 V, 0 – 2.2 A Load Step.
VMIN: 8.87 V, VMAX: 9.27 V.
Upper: VOUT, .5 V / div., 100 ms / div.
Lower: ILOAD, 1 A / div.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page 38 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
12.2 Switching Waveforms
12.2.1 Drain Voltage and Current
Figure 31 – Drain Voltage and Current Waveforms.
85 VAC, 5.0 V, 3 A Load, (240 VMAX).
Upper: VDRAIN, 100 V, 20 s / div.
Lower: IDRAIN, 500 mA / div.
Figure 32 – Drain Voltage and Current Waveforms.
265 VAC, 5 V, 3 A Load, (491 VMAX).
Upper: VDRAIN, 200 V, 20 s / div.
Lower: IDRAIN, 500 mA / div.
Figure 33 – Drain Voltage and Current Waveforms.
85 VAC, 9.0 V, 2.2 A Load, (273 VMAX).
Upper: VDRAIN, 100 V, 20 s / div.
Lower: IDRAIN, 500 mA / div.
Figure 34 – Drain Voltage and Current Waveforms.
265 VAC, 9 V, 2.2 A Load, (527 VMAX).
Upper: VDRAIN, 200 V, 20 s / div.
Lower: IDRAIN, 500 mA / div.
Page 39 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
12.2.2 Drain Voltage and Current Start-up
Figure 35 – Drain Voltage and Current Waveforms.
85 VAC, 5 V, 3 A Load, (241 VMAX)
Upper: VDRAIN, 100 V, 50 ms, 20 s / div.
Lower: IDRAIN, 500 mA / div.
Figure 36 – Drain Voltage and Current Waveforms.
265 VAC, 5 V, 3 A Load, (499 VMAX)
Upper: VDRAIN, 200 V, 50 ms, 20 s / div.
Lower: IDRAIN, 500 mA / div.
12.2.3 SR FET Voltage
Figure 37 – SR FET Voltage Waveforms.
85 VAC, 5 V, 3 A Load, (34.9 VMAX).
VDRAIN, 10 V, 200 s, 10 s / div.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Figure 38 – SR FET Voltage Waveforms.
265 VAC, 5 V, 3 A Load, (75.1 VMAX).
VDRAIN, 20 V, 200 s, 10 s / div.
Page 40 of 54
23-Feb-16
Figure 39 – SR FET Voltage Waveforms.
85 VAC, 9 V, 2.2 A Load, (40.7 VMAX).
VDRAIN, 10 V, 200 s, 10 s / div.
DER-533 20 W USB-PD InnoSwitch-CP Charger
Figure 40 – SR FET Voltage Waveforms.
265 VAC, 9 V, 2.2 A Load, (66.4 VMAX).
VDRAIN, 20 V, 200 s, 10 s / div.
12.2.4 Output Voltage and Current Start-up (at End of the Cable)
Figure 41 – Output Voltage and Current Waveforms.
85 VAC Input, 1.66 Load.
Upper: IOUT, 1 A, 2 ms / div.
Lower: VOUT, 1 V / div.
Page 41 of 54
Figure 42 – Output Voltage and Current Waveforms.
265 VAC Input, 1.66  Load.
Upper: IOUT, 1 A, 2 ms / div.
Lower: VOUT, 1 V / div.
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
12.3 Output Voltage Change (Measured at the End of the Cable)
12.3.1 Output Voltage Change (USB-PD)
12.3.1.1
2.2 A Load
Figure 43 – Output Voltage and Current Waveforms.
85 VAC Input, 2.2 A Load.
Upper: IOUT, 1 A, 2 s / div.
Lower: VOUT, 2 V / div.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Figure 44 – Output Voltage and Current Waveforms.
265 VAC Input, 2.2 A Load.
Upper: IOUT, 1 A, 2 s / div.
Lower: VOUT, 2 V / div.
Page 42 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
12.4 Output Ripple Measurements
12.4.1 Ripple Measurement Technique
For DC output ripple measurements, a modified oscilloscope test probe must be utilized
in order to reduce spurious signals due to pick-up. Details of the probe modification are
provided in the Figures below.
The 4987BA probe adapter is affixed with two capacitors tied in parallel across the probe
tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 47 F/50 V
aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper
polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 45 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 46 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter.
(Modified with wires for ripple measurement, and two parallel decoupling capacitors added)
Page 43 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
12.4.2 Ripple Amplitude vs. Line
12.4.2.1
5.0 V
Input
Max Ripple (mV)
85 VAC
76.5
115 VAC
82.4
230 VAC
98.9
265 VAC
77
Figure 47 – Ripple Amplitude vs. Output Power 5 V.
Power Integrations, Inc.
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Page 44 of 54
23-Feb-16
12.4.2.2
DER-533 20 W USB-PD InnoSwitch-CP Charger
9.0 V
Input
Max Ripple (mV)
85 VAC
100.1
115 VAC
89.6
230 VAC
98.6
265 VAC
104.9
Figure 48 – Ripple Amplitude vs. Output Power 9.0 V.
Page 45 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
12.4.2.3
5V
Figure 49 – Output Ripple.
85 VAC Input 5.0 V, 3 A Load.
VOUT, 50 mV / div., 10 ms / div.
12.4.2.4
23-Feb-16
Figure 50 – Output Ripple.
265 VAC Input 5.0 V, 3 A Load.
VOUT, 50 mV / div., 10 ms / div.
9V
Figure 51 – Output Ripple.
85 VAC Input, 9.0 V, 2.2 A Load.
VOUT, 50 mV / div., 10 ms / div.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Figure 52 – Output Ripple.
265 VAC Input 9.0 V, 2.2 A Load.
VOUT, 50 mV / div., 10 ms / div.
Page 46 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
13 Conducted EMI
13.1 Floating Output (PK / AV)
13.1.1 5 V, 3 A
Power Integrations
15.Feb 16 18:01
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
dBµV
80
1 MHz
Marker 1 [T2 ]
27.45 dBµV
208.303512797 kHz
3 PK
CLRWR
RBW
MT
dBµV
80
1 MHz
PASS
SGL
EN55022Q
60
60
TDF
2 AV
CLRWR
3 PK
CLRWR
40
30 1
PASS
70
EN55022Q
50
Marker 1 [T2 ]
27.26 dBµV
208.303512797 kHz
10 MHz
LIMIT CHECK
EN55022A
9 kHz
20 ms
Att 10 dB AUTO
10 MHz
LIMIT CHECK
70
2 AV
CLRWR
Power Integrations
15.Feb 16 17:57
SGL
EN55022A
TDF
50
40
30 1
6DB
6DB
20
20
10
10
0
0
-10
-10
-20
-20
150 kHz
70 MHz
150 kHz
70 MHz
DAK85_115_NHAND_NOYCAP_NOFUSE
DAK85_115_NHAND_NOYCAP_NOFUSE
Date: 15.FEB.2016
Date: 15.FEB.2016
18:01:04
115 VAC Input
17:57:49
230 VAC Input
Figure 53 – Floating Ground EMI, 5 V / 3 A Load [Line Scan].
Page 47 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
13.1.2 9 V, 2.2 A
Power Integrations
15.Feb 16 18:34
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
dBµV
80
1 MHz
Marker 1 [T2 ]
27.66 dBµV
208.303512797 kHz
3 PK
CLRWR
RBW
MT
dBµV
1 MHz
80
PASS
SGL
SGL
EN55022Q
60
60
TDF
2 AV
CLRWR
3 PK
CLRWR
40
PASS
70
EN55022Q
50
Marker 1 [T2 ]
30.07 dBµV
206.241101780 kHz
10 MHz
LIMIT CHECK
EN55022A
9 kHz
20 ms
Att 10 dB AUTO
10 MHz
LIMIT CHECK
70
2 AV
CLRWR
Power Integrations
15.Feb 16 17:08
EN55022A
TDF
50
40
1
30 1
30
6DB
6DB
20
20
10
10
0
0
-10
-10
-20
-20
150 kHz
70 MHz
150 kHz
70 MHz
DAK85_115_NHAND_NOYCAP_NOFUSE
DAK85_115_NHAND_NOYCAP_NOFUSE
Date: 15.FEB.2016
Date: 15.FEB.2016
18:34:45
115 VAC Input
17:08:56
230 VAC Input
Figure 54 – Floating Ground EMI, 9 V / 2.2 A Load [Line Scan].
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page 48 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
13.2 Artificial Hand Ground (PK / AV)
13.2.1 5 V, 3 A
Power Integrations
15.Feb 16 18:04
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
dBµV
80
1 MHz
Power Integrations
15.Feb 16 18:04
Marker 1 [T2 ]
26.77 dBµV
208.303512797 kHz
dBµV
10 MHz
LIMIT CHECK
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
80
1 MHz
10 MHz
LIMIT CHECK
PASS
Marker 1 [T2 ]
26.77 dBµV
208.303512797 kHz
PASS
70
70
SGL
SGL
2 AV
CLRWR
3 PK
CLRWR
EN55022Q
EN55022Q
60
60
EN55022A
TDF
50
2 AV
CLRWR
3 PK
CLRWR
40
EN55022A
TDF
50
40
30 1
30 1
6DB
6DB
20
20
10
10
0
0
-10
-10
-20
-20
150 kHz
70 MHz
150 kHz
70 MHz
DAK85_115_NHAND_NOYCAP_NOFUSE
DAK85_115_NHAND_NOYCAP_NOFUSE
Date: 15.FEB.2016
Date: 15.FEB.2016
18:04:01
115 VAC Input
18:04:01
230 VAC Input
Figure 55 – Artificial Hand Ground EMI, 5 V / 3 A Load [Line Scan].
Page 49 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
13.2.2 9 V, 2.2 A
Power Integrations
15.Feb 16 18:36
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
dBµV
80
1 MHz
dBµV
9 kHz
20 ms
1 MHz
80
Marker 1 [T2 ]
31.17 dBµV
206.241101780 kHz
10 MHz
LIMIT CHECK
PASS
PASS
70
70
3 PK
CLRWR
RBW
MT
Att 10 dB AUTO
10 MHz
LIMIT CHECK
2 AV
CLRWR
Power Integrations
15.Feb 16 17:10
Marker 1 [T2 ]
27.06 dBµV
208.303512797 kHz
SGL
SGL
EN55022Q
EN55022Q
60
60
EN55022A
TDF
50
2 AV
CLRWR
3 PK
CLRWR
40
EN55022A
TDF
50
40
1
30
30 1
6DB
6DB
20
20
10
10
0
0
-10
-10
-20
-20
150 kHz
70 MHz
150 kHz
70 MHz
DAK85_115_NHAND_NOYCAP_NOFUSE
DAK85_115_NHAND_NOYCAP_NOFUSE
Date: 15.FEB.2016
Date: 15.FEB.2016
18:36:01
115 VAC Input
17:10:37
230 VAC Input
Figure 56 – Artificial Hand Ground EMI, 9 V / 2.2 A Load [Line Scan].
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page 50 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
13.3 Earth Ground (PK / AV)
13.3.1 5 V, 3 A
Power Integrations
15.Feb 16 18:02
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
dBµV
80
1 MHz
Marker 1 [T2 ]
26.03 dBµV
208.303512797 kHz
3 PK
CLRWR
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
dBµV
10 MHz
LIMIT CHECK
1 MHz
80
PASS
SGL
SGL
EN55022Q
60
60
TDF
50
2 AV
CLRWR
3 PK
CLRWR
40
30 1
PASS
70
EN55022Q
EN55022A
Marker 1 [T2 ]
28.77 dBµV
208.303512797 kHz
10 MHz
LIMIT CHECK
70
2 AV
CLRWR
Power Integrations
15.Feb 16 17:55
EN55022A
TDF
50
40
30
1
6DB
6DB
20
20
10
10
0
0
-10
-10
-20
-20
150 kHz
70 MHz
150 kHz
70 MHz
DAK85_115_NHAND_NOYCAP_NOFUSE
DAK85_115_NHAND_NOYCAP_NOFUSE
Date: 15.FEB.2016
Date: 15.FEB.2016
18:02:32
115 VAC Input
17:55:56
230 VAC Input
Figure 57 – Earth Ground EMI, 5 V / 3 A Load [Line Scan].
Page 51 of 54
Power Integrations
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DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
13.3.2 9 V, 2.2 A
Power Integrations
15.Feb 16 18:37
RBW
MT
9 kHz
20 ms
Att 10 dB AUTO
dBµV
80
1 MHz
Marker 1 [T2 ]
27.18 dBµV
208.303512797 kHz
Power Integrations
15.Feb 16 17:05
dBµV
10 MHz
LIMIT CHECK
10 MHz
LIMIT CHECK
EN55022Q
60
60
TDF
50
2 AV
CLRWR
3 PK
CLRWR
40
PASS
SGL
EN55022Q
EN55022A
Marker 1 [T2 ]
29.65 dBµV
206.241101780 kHz
70
SGL
3 PK
CLRWR
9 kHz
20 ms
1 MHz
80
PASS
70
2 AV
CLRWR
RBW
MT
Att 10 dB AUTO
EN55022A
TDF
50
40
1
30 1
30
6DB
6DB
20
20
10
10
0
0
-10
-10
-20
-20
150 kHz
70 MHz
150 kHz
70 MHz
DAK85_115_NHAND_NOYCAP_NOFUSE
DAK85_115_NHAND_NOYCAP_NOFUSE
Date: 15.FEB.2016
Date: 15.FEB.2016
18:37:22
115 VAC Input
17:05:44
230 VAC Input
Figure 58 – Earth Ground EMI, 9 V / 2.2 A Load [Line Scan].
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.power.com
Page 52 of 54
23-Feb-16
DER-533 20 W USB-PD InnoSwitch-CP Charger
14 Revision History
Date
18-Feb-16
19-Feb-16
23-Feb-16
Page 53 of 54
Author
AK
RJ
RJ
Revision
1.0
1.1
1.2
Description & Changes
Initial Release
Minor Edits
Minor Edits
Reviewed
Power Integrations
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www.power.com
DER-533 20 W USB-PD InnoSwitch-CP Charger
23-Feb-16
For the latest updates, visit our website: www.power.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.power.com. Power Integrations grants its
customers a license under certain patent rights as set forth at http://www.power.com/ip.htm.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, LYTSwitch, InnoSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS,
HiperLCS, Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, FluxLink, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations,
Inc. Other trademarks are property of their respective companies. ©Copyright 2015 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]
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Phone: +65-6358-2160
Fax: +65-6358-2015
e-mail:
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1.
Power Integrations, Inc.
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Page 54 of 54
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