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 www.power.com 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 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 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 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 3 Schematic Figure 3 – Schematic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 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 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 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 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 www.power.com 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 100kHz, 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations 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 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 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 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations 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 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 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations 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 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 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 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 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 280 DER-533 20 W USB-PD InnoSwitch-CP Charger 23-Feb-16 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations 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 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 280 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 100 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. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 www.power.com 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 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 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. 85VAC, 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. 265VAC, 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 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 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 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 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 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 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. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 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 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 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 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 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 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 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 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 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. 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