Engineering Prototype Report for 2.0 W CV Adapter using LNK362P Title Specification 85-265 VAC Input, 6.2 V, 322 mA Output Application Low Cost Adapter Author Power Integrations Applications Department Document Number EPR-89 Date 08-Nov-05 Revision 1.0 Summary and Features • • • • • Low cost, low part count solution: requires only 19 components Integrated LinkSwitch-XT safety and reliability features: • Accurate (± 5%), auto-recovering, hysteretic, thermal shutdown function keeps PCB temperature below safe levels under all conditions • Auto-restart protects against output short-circuits and open feedback loops • > 3.2 mm creepage on IC package enables reliable operation in high humidity and high pollution environments EcoSmart® – meets all existing and proposed international energy efficiency standards such as China (CECP) / CEC / EPA / AGO / European Commission • No-load consumption 110 mW at 265 VAC • 61.5 % active-mode efficiency (exceeds CEC requirement of 55.2 %) E-Shield™ transformer construction and frequency jitter enable this supply to meet EN550022 & CISPR-22 Class B EMI with >10 dBµV of margin Meets IEC61000-4-5 Class 3 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. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 Table Of Contents 1 2 3 4 Introduction.................................................................................................................3 Power Supply Specification ........................................................................................5 Schematic...................................................................................................................6 Circuit Description ......................................................................................................7 4.1 Input Filter ...........................................................................................................7 4.2 LNK362 Primary ..................................................................................................7 4.3 Feedback.............................................................................................................8 5 PCB Layout ................................................................................................................9 6 Bill Of Materials ........................................................................................................10 7 Transformer Specification.........................................................................................11 7.1 Electrical Diagram .............................................................................................11 7.2 Electrical Specifications.....................................................................................11 7.3 Materials............................................................................................................11 7.4 Transformer Build Diagram ...............................................................................12 7.5 Transformer Construction..................................................................................12 8 Design Spreadsheets ...............................................................................................13 9 Performance Data ....................................................................................................16 9.1 Efficiency ...........................................................................................................16 9.1.1 Active Mode Efficiency (CEC) Measurement Data .....................................16 9.2 No-load Input Power..........................................................................................17 9.3 Available Standby Output Power.......................................................................18 9.4 Regulation .........................................................................................................19 9.4.1 Load ...........................................................................................................19 9.4.2 Line ............................................................................................................20 10 Thermal Performance ...........................................................................................20 11 Waveforms............................................................................................................22 11.1 Drain Voltage and Current, Normal Operation...................................................22 11.2 Output Voltage Start-up Profile..........................................................................22 11.3 Drain Voltage and Current Start-up Profile ........................................................23 11.4 Load Transient Response (75% to 100% Load Step) .......................................23 11.5 Output Ripple Measurements............................................................................24 11.5.1 Ripple Measurement Technique ................................................................24 11.5.2 Measurement Results ................................................................................25 12 Line Surge.............................................................................................................26 13 Conducted EMI .....................................................................................................27 14 Revision History ....................................................................................................28 Important Note: Although this board has been 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 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 1 Introduction This engineering report describes a 2.0 W CV, universal input, power supply for applications such as wall adapters. The supply is designed around a LNK362P device, and is intended as a standard evaluation platform for the LinkSwitch-XT family of ICs. Figure 1 – EP89, LNK362P, 2.0 W, 6.2 V, CV Charger Board Photograph. The LinkSwitch-XT family has been developed to replace discrete component selfoscillating, ringing choke converters (RCC) and linear regulator-based supplies, in low power adapter applications. The ON/OFF control scheme of the device family achieves very high efficiency over the full load range, as well as very low no-load power consumption. The no-load and active-mode efficiency performance of this supply exceeds all current and proposed energy efficiency standards. Unlike RCC solutions, the LinkSwitch-XT has intelligent thermal protection built in, eliminating the need for external circuitry. The thermal shutdown has a tight tolerance (142 °C ± 5%), a wide hysteresis (75 °C) and recovers automatically once the cause of the over temperature condition is removed. This protects the supply, the load and the user, and typically keeps the average PCB temperature below 100 °C. In contrast, the latching thermal shutdown function typically used in RCC designs usually requires that the AC input power be removed to reset it. Thus, with an RCC, there is fair probability that units may be returned after a thermal latch-off, because the customer is not aware of the reset procedure (unplugging the unit long enough for the input capacitor to discharge). Regardless of the fact that the units being returned are fully functional, this makes the design appear to be less reliable to both the OEM and the end customer, and burdens the power supply manufacturer with the needless handling of perfectly good units through its RMA process. Page 3 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 On the other hand, an auto-recovering thermal shutdown function eliminates the occurrence of unnecessary returns from the field, since the end customer may never even know that a fault condition existed, because the power supply resumes normal operation once the cause of the fault (a failed battery or blanket inadvertently thrown over top of a working power adapter or battery charger) is removed. Additionally, the thermal shutdown function employed in the LinkSwitch-XT does not have the noise sensitivity associated with discrete latch circuits, which often vary widely with PCB component layout, environmental conditions (such as proximity to external electronic noise sources) and component aging. The IC package has a wide creepage distance between the high-voltage DRAIN pin and the lower voltage pins (both where the pins exit the package and at the PCB pads). This is important for reliable operation in high humidity and/or high pollution environments. The wide creepage distance reduces the likelihood of arcing, which improves robustness and long-term field reliability. Another important protection function is auto-restart, which begins operating whenever there is no feedback from the power supply output for more than 40 ms (such as a short circuit on the output or a component that has failed open-circuit in the feedback loop). Auto-restart limits the average output current to about 5 % of the full load rating indefinitely, and resumes normal operation once the fault is removed. The worst-case, no-load power consumption of this design is about 110 mW at 265 VAC, which is well below the 300 mW European Union standards. It also meets the common target of 150 mW at 230 VAC, that is seen in many particular customer specifications. The amount of heat dissipated within the supply is minimized by the high operating efficiency over all combinations of load and line. The EE16 transformer bobbin that was used also has a wide creepage spacing, which makes it easy to meet primary-to-secondary safety spacing requirements. This report contains the complete specification of the power supply, a detailed circuit diagram, the entire bill of materials required to build the supply, extensive documentation of the power transformer, along with test data and oscillographs of the most important electrical waveforms. All of this is intended to document the performance characteristics that should be typical of a power supply designed around the LNK362 device. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 2 Power Supply Specification Description Symbol Min Typ Max Units Comment 265 64 0.15 VAC Hz W 2 Wire – no P.E. 50/60 6.63 V mV mA 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 Efficiency Full Load VIN fLINE 85 47 VOUT1 VRIPPLE1 IOUT1 5.77 η 60 % Measured at POUT 115 VAC, 25 C Required average active efficiency at 25, 50, 75 and 100 % of POUT ηCEC 55.2 % Per California Energy Commission (CEC) / Energy Star requirements 6.2 60 322 2.0 POUT W o Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge Ambient Temperature Page 5 of 32 >6 dB Margin 1.5 TAMB 0 kV 40 o C 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω Free convection, sea level Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 3 Schematic Figure 2 – DAK 89 Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 4 Circuit Description This converter is configured as a flyback. The output voltage is sensed and compared to a reference (VR1) on the secondary side of the supply, and the results are fed back to U1 (LNK362P) through optocoupler U2 (PC817A). This enables U1 to tightly regulate the output voltage across the entire load range. Past the point of peak power delivery, U1 will go into auto-restart, and the average power delivered to the load will be limited to about 5% of full load. This circuit takes advantage of Power Integrations Clampless™ transformer techniques, which use the primary winding capacitance of the transformer to clamp the voltage spike that is induced on the drain-node, by the transformer leakage inductance, each time the integrated MOSFET switch within U1 turns off. Therefore, this converter has no primary clamp components connected to the drain-node. 4.1 Input Filter Diodes D1 through D4 rectify the AC input. The resulting DC is filtered by bulk storage capacitors C1 and C2. Inductor L1 and capacitors C1 and C2 form a pi (π) filter that attenuates differential-mode conducted EMI noise. Resistor R1 dampens the ringing of the EMI filter. L2 also attenuates conducted EMI noise in the primary return. This configuration, combined with the LinkSwitch-XT‘s integrated switching frequency jitter function and Power Integrations E-shield technology used in the construction of the transformer enable this design to meet EN55022 Class-B conducted EMI requirements with good margin. An optional 100 pF Y capacitor (C4) can be used to improve the unitto-unit repeatability of the EMI measurements. Even with C4 installed, the line frequency leakage current is less than 10 µA. 4.2 LNK362 Primary The LNK362P (U1) has the following functions integrated onto a monolithic IC: a 700 V power MOSFET, a low-voltage CMOS controller, a high-voltage current source (provides startup and steady-state operational current to the IC), hysteretic thermal shutdown and auto-restart. The excellent switching characteristics of the integrated power MOSFET allows efficient operation up to 132 kHz. The rectified and filtered input voltage is applied to one side of the primary winding of T1. The other side of the T1 primary winding is connected to the DRAIN pin of U1. As soon as the voltage across the DRAIN and SOURCE pins of U1 exceeds 50 V, the internal high voltage current source (connected to the DRAIN pin of the IC) begins charging the capacitor (C3) connected to the Bypass (BP) pin. Once the voltage across C3 reaches 5.8 V, the controller enables MOSFET switching. MOSFET current is sensed (internally) by the voltage developed across the DRAIN-to-SOURCE resistance (RDS(ON)) while it is turned on. When the current reaches the preset (internal) current-limit trip point (ILIMIT), the controller turns the MOSFET off. The controller also has a maximum duty cycle (DCMAX) signal that will turn the MOSFET off if ILIMIT is not reached before the time duration equal to maximum duty cycle has elapsed. Page 7 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 The controller regulates the output voltage by skipping switching cycles (ON/OFF control) whenever the output voltage is above the reference level. During normal operation, MOSFET switching is disabled whenever the current flowing into the FEEDBACK (FB) pin is greater than 49 µA. If less than 49 µA is flowing into the FB pin when the oscillator’s (internal) clock signal occurs, MOSFET switching is enabled for that switching cycle and the MOSFET turns on. That switching cycle terminates when the current through the MOSFET reaches ILIMIT, or the DCMAX signal occurs*. At full load, few switching cycles will be skipped (disabled) resulting in a high effective switching frequency. As the load reduces, more switching cycles are skipped, which reduces the effective switching frequency. At no-load, most switching cycles are skipped, which is what makes the no-load power consumption of supplies designed around the LinkSwitch-XT family so low, since switching losses are the dominant loss mechanism at light loading. Additionally, since the amount of energy per switching cycle is fixed by ILIMIT, the skipping of switching cycles gives the supply a fairly consistent efficiency over most of the load range. [NOTE * Termination of a switching cycle by the maximum duty cycle (DCMAX) signal usually only occurs in an abnormal condition, such as when a highline-only design (220/240 VAC) is subject to a brown-out condition, where just slightly over 50 V (the minimum drain voltage required for normal operation) is available to the supply, and the current through the MOSFET is not reaching ILIMIT each switching cycle because of the low input voltage.] 4.3 Feedback The output voltage of the supply is determined by the sum of the voltages developed across VR1, R2 and the (forward bias voltage) LED in optocoupler U2A. As the supply turns on and the output voltage comes into regulation, U2A will become forward biased, which will turn on its photo-transistor (U2B) causing > 49 µA to flow into the FB pin, and the next switching cycle to be skipped. Resistor R2 limits the bias current through VR1 to about 1 mA. Resistor R3 can be used to fine-tune the output voltage, and also limits the peak current through U2A during load transients. Since the controller responds to feedback each switching cycle (the decision to enable or disable MOSFET switching is made right before that switching cycle is to occur), the feedback loop requires no frequency compensation components. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 5 PCB Layout Figure 3 – Printed Circuit Board Layout (dimensions in 0.001”). Page 9 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 6 Bill Of Materials Part Qty Value Ref 1 C1 C2 2 3.3 uF Item 2 C3 1 100 nF 3 C4 4 C5 1 1 100 pF 330 uF Description Manufacturer Part # Manufacturer 3.3 uF, 400 V, Electrolytic, (8 x 11.5) 100 nF, 50 V, Ceramic, Z5U, 0.2 Lead Space 100 pF, Ceramic, Y1 330 uF, 16 V, Electrolytic, Very Low ESR, 72 mΩ, (8 x 11.5) TAQ2G3R3MK0811MLL3 Taicon Corporation C317C104M5U5CA 440LT10 EKZE160ELL331MHB5D 5 D1 D2 4 D3 D4 6 D5 1 1N4005 600 V, 1 A, Rectifier, DO-41 1N4005 1N4934 1N4934 7 J1 J2 2 CON1 8 J3 1 Output Cable Assembly 100 V, 1 A, Fast Recovery, 200 ns, DO-41 Test Point, WHT,THRU-HOLE MOUNT 6 ft, 22 AWG, 0.25 Ω, 2.1 mm connector (custom) 9 JP1 1 J 298 10 L1 L2 2 1 mH Wire Jumper, Non insulated, 22 AWG, 0.3 in 1 mH, 0.15 A, Ferrite Core 11 R1 1 3.9 kΩ 3.9 kΩ, 5%, 1/8 W, Carbon Film CFR-12JB-3K9 12 R2 1 1 kΩ 1 kΩ, 5%, 1/8 W, Carbon Film 13 R3 1 390 Ω 390 Ω, 5%, 1/8 W, Carbon Film CFR-12JB-390R 14 RF1 1 8.2 Ω 8.2 Ω, 2.5 W, Fusible/Flame Proof Wire Wound CRF253-4 5T 8R2 Transformer, EE16, Horizontal, 10 pins LinkSwitch-XT, LNK362P, DIP-8B Opto-coupler, 35 V, CTR 80160%, 4-DIP 5.1 V, 500 mW, 2%, DO-35 SNX-1378 LSLA40343 LNK362P 15 T1 1 EE16 16 U1 1 LNK362P 17 U2 1 PC817A 18 VR1 1 BZX79B5V1 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 5012 SBCP-47HY102B CFR-12JB-1K0 Kemet Vishay Nippon ChemiCon Vishay Vishay Keystone Alpha Tokin Yageo Yageo Yageo Vitrohm PC817X1 BZX79-B5V1 Santronics Li Shin Power Integrations Sharp Vishay Page 10 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 7 Transformer Specification 7.1 Electrical Diagram 5 WD#1 Cancillatinon 37T #39X2 Floating Floating WD#3 Shield 10T #33X4 5 9 13 T #27 TIW WD#4 Secondary 8 4 WD#2 Primary 144T #39 3 Figure 4 – Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 1 second, 60 Hz, from Pins 3,4,5 to Pins 8,9 Pins 3-4, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 3-4, all other windings open Pins 3-4, with Pins 8-9 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 2.64 mH, +/-12% 275 kHz (Min.) 500 kHz (Max) 70 µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: PC40EE16-Z, TDK or equivalent gapped for AL of 127 nH/t2 Bobbin: Horizontal 10 pin Magnet Wire: #39 AWG Magnet Wire: #33 AWG Triple Insulated Wire: #27 AWG Tape, 3M 1298 Polyester Film, 2.0 Mils thick, 8.0 mm wide Varnish Page 11 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 7.4 08-Nov-2005 Transformer Build Diagram Tape WD #4 Secondary Pin 5 Pin 8 Pin 9 Tape WD #3 Shield Tape WD #2 Primary Tape WD #1 Cancellation Pin 4 Pin 3 Pin 5 Figure 5 – Transformer Build Diagram. 7.5 Transformer Construction WD #1 Cancellation Winding Insulation WD #2 Primary Winding Insulation WD #3 Shield Winding Insulation WD #4 Secondary Winding Outer insulation Core Assembly Varnish Primary pin side of the bobbin oriented to left hand side. Temporarily start at pin 6. Wind 37 bifilar turns of item [3] from right to left. Wind with tight tension across bobbin evenly. Cut at end. Finish start on pin 5. 1 Layer of tape [6] for insulation. Start at Pin 3. Wind 72 turns of item [3] from left to right. Then wind another 72 turns on the next layer from right to left. Terminate the finish on pin 4. Wind with tight tension across bobbin evenly. Use one layer of tape [6] for basic insulation. Starting at Pin 6 temporarily, wind 10 quadfilar turns of item [4]. Wind from right to left with tight tension across entire bobbin width. Finish on pin 5. Cut at the start lead. Use one layer of tape [6] for basic insulation. Start at Pin 9, wind 13 turns of item [5] from right to left. Spread turns evenly across bobbin. Finish on Pin 8. Wrap windings with 3 layers of tape [6]. Assemble and secure core halves. Dip varnish assembly with item [7]. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 8 Design Spreadsheets ACDC_LinkSwitch -XT_101205; Rev.1.2; INPUT Copyright Power Integrations 2005 ENTER APPLICATION VARIABLES VACMIN 85 VACMAX 265 fL 50 INFO OUTPUT EP89 Volts Volts Hertz VO 6.20 Volts IO 0.32 Amps 0.00 Volts CC Threshold Voltage Output Cable Voltage Resistance PO 2.00 Watts Output Power (VO x IO + CC dissipation) Enter 'BIAS' for Bias winding feedback and 'OPTO' for Optocoupler feedback Enter 'YES' to add a Bias winding. Enter 'NO' to continue design without a Bias winding. Addition of Bias winding can lower no load consumption !!! Caution. For designs above 2 W and no Bias winding, Verify peak Drain Voltage and EMI performance Efficiency Estimate at output terminals. Loss Allocation Factor (suggest 0.5 for CC=0 V, 0.75 for CC=1 V) Bridge Rectifier Conduction Time Estimate Input Capacitance Choose H for Half Wave Rectifier and F for Full Wave Rectification Add Bias Winding No Clampless design (LNK 362 only) Yes n 0.63 0.63 Z 0.50 0.5 tC CIN Input Rectification Type 2.90 6.60 No Caution Clampless mSeconds uFarads F LNK362 77.00 0.75 User selection for LinkSwitch-XT LNK362 0.130 Amps 0.150 Amps 124000 Hertz 2199 A^2Hz VDS VD KP Page 13 of 32 Opto F VOR Voltage drop across sense resistor. Enter the resistance of the output cable (if used) Opto I^2fmin Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage (main) (For CC designs enter upper CV tolerance limit) Power Supply Output Current (For CC designs enter upper CC tolerance limit) 0.17 Ohms Feedback Type ENTER LinkSwitch-XT VARIABLES LinkSwitch-XT LNK362 Chosen Device ILIMITMIN ILIMITMAX fSmin ACDC_LinkSwitch-XT_101205_Rev1-2.xls; LinkSwitch-XT Continuous/Discontinuous Flyback Transformer Design Spreadsheet UNIT 77 Volts 10 Volts 0.75 Volts 1.00 Minimum Current Limit Maximum Current Limit Minimum Device Switching Frequency I^2f (product of current limit squared and frequency is trimmed for tighter tolerance) VOR > 90V not recommended for Clampless designs with no Bias windings. Reduce VOR below 90V LinkSwitch-XT on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.6 < KP < 6.0) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type Core EE16 Bobbin EE16_BOBBIN AE LE AL BW 08-Nov-2005 NS NB VB PIVB 13 N/A N/A Volts N/A Volts Suggested smallest commonly available core PC40EE16-Z EE16_BOBBIN 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) L > 2 or L < 1 not recommended for Clampless designs with no Bias windings. Enter L = 2 Number of Secondary Turns Bias winding not used Bias winding not used N/A - Bias Winding not in use DC INPUT VOLTAGE PARAMETERS VMIN VMAX 87 Volts 375 Volts Minimum DC Input Voltage Maximum DC Input Voltage CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS 0.50 0.04 0.13 0.12 0.06 Maximum Duty Cycle Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP_TOLERANCE 12.00 NP ALG 2677 uHenries 12 % 144 129 nH/T^2 BM 1452 EE16 0.192 3.5 1140 8.6 P/N: P/N: cm^2 cm nH/T^2 mm M 0 mm L 2 BAC 553 ur LG BWE OD INS DIA 1654 0.17 17.2 0.12 0.03 0.09 AWG 39 CM CMA 13 225 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Amps Amps Amps Amps Typical Primary Inductance. +/- 12% Primary inductance tolerance Primary Winding Number of Turns Gapped Core Effective Inductance Maximum Operating Flux Density, BM<1500 is Gauss recommended AC Flux Density for Core Loss Curves (0.5 X Peak to Gauss Peak) Relative Permeability of Ungapped Core mm Gap Length (Lg > 0.1 mm) mm Effective Bobbin Width mm Maximum Primary Wire Diameter including insulation mm Estimated Total Insulation Thickness (= 2 * film thickness) mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG AWG value) Cmils Bare conductor effective area in circular mils Cmils/Amp Primary Winding Current Capacity (150 < CMA < 500) Page 14 of 32 08-Nov-2005 TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP ISRMS IRIPPLE CMS AWGS EP-89 6.2 V, 322 mA Adapter 1.44 0.63 0.54 125 Amps Amps Amps Cmils 29 AWG DIAS 0.29 mm ODS 0.66 mm INSS 0.19 mm Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current 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 PIVS - Volts 40 Volts For Clampless designs, the 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 FEEDBACK COMPONENTS Recommended Bias Diode 1N4003 1N4007 R1 500 ohms 1000 R2 200 - 820 ohms Recommended diode is 1N4003. Place diode on return leg of bias winding for optimal EMI. See LinkSwitch-XT Design Guide CV bias resistor for CV/CC circuit. See LinkSwitch-XT Design Guide Resistor to set CC linearity for CV/CC circuit. See LinkSwitchXT Design Guide TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 Recommended Diodes Pre-Load Resistor CMS1 AWGS1 DIAS1 ODS1 Page 15 of 32 6.20 Volts 0.32 2.00 0.75 13.00 0.63 0.54 40.03 UF4001, SB150 Amps Watts Volts Amps Amps Volts 2 k-Ohms 126.56 Cmils 29.00 AWG 0.29 mm 0.66 mm 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 Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Recommended Diodes for this output 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 9 Performance Data All measurements performed at room temperature (25 °C), 60 Hz input frequency. 9.1 Efficiency 68 66 Efficiency % 64 62 60 85 VAC 58 115 VAC 230 VAC 265 VAC 56 54 0 0.5 1 1.5 2 2.5 Output Power (W) Figure 6 – Efficiency vs. Output Power. % of Full Load 25 50 75 100 Average Efficiency CEC Requirement % Efficiency @ 115 VAC 63.3 65.2 64.9 64.9 64.6 % Efficiency @ 230VAC 58.2 61.4 63.0 63.2 61.5 55.2 Figure 7 – Efficiency vs. Input Voltage and Load, Room Temperature, 60 Hz. 9.1.1 Active Mode Efficiency (CEC) Measurement Data All single output adapters, including those provided with products, for sale in California after July 1st, 2006 must meet the California Energy Commission (CEC) requirement for minimum active mode efficiency and no-load input power consumption. Minimum active mode efficiency is defined as the average efficiency at 25, 50, 75 and 100% of rated output power, based on the nameplate rated output power of the supply. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 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 W For adapters that are rated for a single input voltage, the efficiency measurements are made at the input voltage (115 VAC or 230 VAC) specified on the nameplate. For universal input adapters, the measurements are made at both nominal input voltages (115 VAC and 230 VAC). To comply with the standard, the average of the measured efficiencies must be greater than or equal to the efficiency specified by the CEC/Energy Star standard. More states within the USA and other countries are adopting this standard, for the latest up to date information on worldwide energy efficiency standards, please visit the PI Green Room at: http://www.powerint.com/greenroom/regulations.htm 9.2 No-load Input Power 0.12 Input Power (W) 0.1 0.08 0.06 0.04 0.02 0 0 50 100 150 200 250 300 Input Voltage (VAC) Figure 8 – No-load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. Page 17 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 9.3 Available Standby Output Power The graph below shows the available output power vs line voltage when input power is limited to 1 W and 2 W, respectively. 1.4 Output Power (W) 1.2 1 Pin = 1.0 W Pin = 2.0 W 0.8 0.6 0.4 0.2 0 0 50 100 150 200 250 300 Input Voltage (VAC) Figure 9 – Available Output Power for Input Power of 1 W and 2 W. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 32 08-Nov-2005 9.4 EP-89 6.2 V, 322 mA Adapter Regulation 9.4.1 Load The output of this supply was characterized by making measurements at the end of a 6 foot long output cable. The DC resistance of the cable is approximately 0.2 Ω. Output Voltage (Volts) 7 6.5 6 115 VAC 5.5 230 VAC Upper Limit Lower Limit 5 0 50 100 150 200 250 300 350 Output Current (mA) Figure 10 – Load Regulation, Room Temperature. Page 19 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 9.4.2 Line Output Voltage (VDC) 7 6.5 6 5.5 5 0 50 100 150 200 250 300 Input Voltage (VAC) Figure 11 – Line Regulation, Room Temperature, Full Load. 10 Thermal Performance Thermal performance was measured inside a plastic enclosure, at full load, with no airflow over the power supply components or the housing they were enclosed within. Item Ambient LNK362P (source pin) 90 VAC 265 VAC 40°C 40°C 93.0°C at 2.0 W output (6.2V, 322mA) 111.8°C at 2.0 W output (6.2V, 322mA). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 85 VAC, 2 W load, 22 °C Ambient 265 VAC, 2 W load, 22 °C Ambient Figure 12 – Infra-red Thermograph of Operating Unit: Open Frame, 22 °C Ambient. Page 21 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 11 Waveforms 11.1 Drain Voltage and Current, Normal Operation Figure 13 – 85 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V / div. Figure 14 – 265 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V / div. 11.2 Output Voltage Start-up Profile Figure 15 – Start-up Profile, 115 VAC. 1 V, 20 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 16 – Start-up Profile, 230 VAC. 1 V, 20 ms / div. Page 22 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 11.3 Drain Voltage and Current Start-up Profile Figure 17 – 85 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V & 1 ms / div. Figure 18 – 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V & 1 ms / div. 11.4 Load Transient Response (75% to 100% Load Step) Figure 19 – Transient Response, 115 VAC, 100-75100% Load Step. Output Voltage 50 mV, 20 ms / div. Page 23 of 32 Figure 20 – Transient Response, 230 VAC, 100-75100% Load Step. Output Voltage 50 mV, 20 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 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 spurious signals due to pickup. Details of the probe modification are provided in Figure 21 and Figure 22. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 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 below). Probe Ground Probe Tip Figure 21 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 22 – Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 11.5.2 Measurement Results Figure 23 – Ripple, 85 VAC, Full Load. 50 us, 20 mV / div. Figure 24 – 5 V Ripple, 115 VAC, Full Load. 50 us, 20 mV / div. Figure 25 – Ripple, 230 VAC, Full Load. 50 us, 20 mV / div. Figure 26 – Ripple, 265 VAC, Full Load. 50 us, 20 mV / div. Page 25 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 12 Line Surge Differential input line 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. Output was loaded at full load and operation was verified following each surge event. Surge Level (V) +500 -500 +750 -750 +1000 -1000 +1500 -1500 Input Voltage (VAC) 230 230 230 230 230 230 230 230 Injection Location Injection Phase (°) Test Result (Pass/Fail) L to N L to N L to N L to N L to N L to N L to N L to N 90 90 90 90 90 90 90 90 Pass Pass Pass Pass Pass Pass Pass Pass Unit passes under all test conditions. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter 13 Conducted EMI Power Integrations 27.Oct 05 15:50 Att 10 dB AUTO dBµV 1 MHz 80 RBW 9 kHz Marker 1 [T1 ] MT 500 ms 35.01 dBµV PREAMP OFF 182.849162999 kHz 10 MHz LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG 70 1 QP EN55022Q CLRWR 60 SGL 2 AV EN55022A CLRWR 50 TDF 40 1 30 20 10 0 -10 -20 150 kHz 30 MHz DAK 89: 115VAC with ARTIFICIAL HAND Date: 27.OCT.2005 15:50:22 Figure 27 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, Artificial Hand and EN55022 B Limits. Power Integrations 27.Oct 05 16:02 Att 10 dB AUTO dBµV 80 RBW 9 kHz Marker 1 [T1 ] MT 500 ms 29.68 dBµV PREAMP OFF 182.849162999 kHz 1 MHz 10 MHz LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG 70 1 QP EN55022Q CLRWR 60 SGL 2 AV EN55022A CLRWR 50 TDF 40 1 30 20 10 0 -10 -20 150 kHz 30 MHz DAK 89: 230VAC with ARTIFICIAL HAND Date: 27.OCT.2005 16:02:19 Figure 28 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, Artificial Hand and EN55022 B Limits. Page 27 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 14 Revision History Date 08-Nov-05 Author JAJ Revision 1.0 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Description & changes Formatted for Final Release Page 28 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter Notes Page 29 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 Notes Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 32 08-Nov-2005 EP-89 6.2 V, 322 mA Adapter Notes Page 31 of 32 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EP-89 6.2 V, 322 mA Adapter 08-Nov-2005 For the latest updates, visit our website: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND 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, 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 2005 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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