Design Example Report Title 5 W, 5 V Charger using TNY274P Specification Input: 85 – 264 VAC Output: 5 V / 1 A Application Portable Audio / MP3 Player Author Power Integrations Applications Department Document Number DER-113 Date July 19, 2006 Revision 1.1 Summary and Features • • • • • • CVCC adapter High Efficiency Meets CEC efficiency and no-load specs <100 mW No Load Consumption Low conducted EMI without Y cap CC mode has good temperature compensation 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 DER-113 5 W Charger for Portable Audio Player July 19, 2006 Table Of Contents 1 2 3 4 Introduction .................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic ...................................................................................................................5 Circuit Description.......................................................................................................6 4.1 Primary clamp snubber........................................................................................6 4.2 Bias supply ..........................................................................................................6 4.3 CVCC circuit ........................................................................................................6 5 PCB Layout.................................................................................................................7 6 Bill Of Materials...........................................................................................................8 7 Transformer Specification ...........................................................................................9 7.1 Electrical Diagram................................................................................................9 7.2 Electrical Specifications .......................................................................................9 7.3 Materials ..............................................................................................................9 7.4 Transformer Build Diagram................................................................................10 7.5 Transformer Construction ..................................................................................10 8 Transformer Spreadsheets .......................................................................................11 9 Performance Data.....................................................................................................14 9.1 Efficiency ...........................................................................................................14 9.1.1 Active Mode CEC Measurement Data........................................................15 9.2 No-load Input Power ..........................................................................................16 9.3 Regulation .........................................................................................................16 9.3.1 Output Characteristic..................................................................................16 10 Thermal Performance............................................................................................17 11 Waveforms ............................................................................................................18 11.1 Drain Voltage and Current, Normal Operation...................................................18 11.2 Output Voltage Start-up Profile ..........................................................................18 11.3 Drain Voltage and Current Start-up Profile ........................................................19 11.4 Load Transient Response (75% to 100% Load Step)........................................20 11.5 Output Ripple Measurements ............................................................................21 11.5.1 Ripple Measurement Technique.................................................................21 11.5.2 Measurement Results.................................................................................22 12 Conducted EMI .....................................................................................................23 13 Revision History ....................................................................................................24 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 2 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 1 Introduction This document is an engineering report describing a design for a 5 V / 1 A adapter. The power supply utilizes a TNY274 as the switching controller. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. Figure 1 – Populated Circuit Board Photograph. Page 3 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 2 Power Supply Specification Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage (CV) Output Voltage (CC) Output Ripple Voltage Output Current Total Output Power Continuous Output Power Efficiency Full Load Required average efficiency at 25, 50, 75 and 100 % of POUT Symbol Min Typ Max Units Comment VIN fLINE 85 47 265 64 0.3 VAC Hz W 2 Wire – no P.E. 50/60 VOUT VOUT VRIPPLE IOUT 4.75 5.25 100 1 V V mV A 5 W 5 1 0 POUT η 68 ηCEC 63.5 70 ± 5% CC prior to auto-restart 20 MHz bandwidth CV Operation Mode o % Measured at POUT 25 C % Per California Energy Commission (CEC) / Energy Star requirements Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge Ambient Temperature Page 4 of 25 1.5 TAMB 0 kV 50 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 DER-113 5 W Charger for Portable Audio Player July 19, 2006 3 Schematic Figure 2 – Schematic. Page 5 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 4 Circuit Description 4.1 Primary clamp snubber D5 is a normal recovery, glass passivated 1N4007G for good EMI and higher efficiency. If the glass passivated version of the 1N4007 is not available then the FR107 is recommended. Standard plastic 1N4007 types are not recommended due to excessive drain ringing. 4.2 Bias supply D6, C5 and R3 provide a small bias current to the TNY274 to reduce no-load consumption and reduce its temperature. 4.3 CVCC circuit Transistors Q1-Q3, and associated resistors form the constant current regulation circuit. Resistor R8 and R7 form the current sense resistor. In CC mode the voltage drop on it is regulated to 0.35 V. This CC circuit has built in temperature compensation. VR1 regulates the output in CV mode. Page 6 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 5 PCB Layout Figure 3 – Printed Circuit Layout. Page 7 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 6 Bill Of Materials Item Qty Part Reference Value Description 1 2 C1 C2 6.8 uF 6.8 uF, 400 V, Electrolytic, (10 x 16), 2 1 C3 100 nF 100 nF, 50 V, Ceramic, Z5U 3 1 C4 1 nF 4 1 C5 4.7 uF 5 1 C6 1 nF 6 1 C7 1000 uF 1 nF, 1 kV, Disc Ceramic 4.7 uF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) 1 nF, 100 V, Ceramic, X7R 1000 uF, 10 V, Electrolytic, Very Low ESR, 41 mOhm, (8 x 20) 10 nF, 50 V, Ceramic, Z5U 7 1 C8 10 nF 8 4 D1 D2 D3 D4 1N4007 9 1 D5 1N4007GP 10 1 D6 1N4148 75 V, 300 mA, Fast Switching, DO-35 11 1 D7 SB330 30 V, 3 A, Schottky, DO-201AD 12 1 HS1 13 1 L1 14 1 L2 15 2 Q1 Q2 2N3904 16 1 Q3 2N3906 17 1 R1 200 k 18 1 R2 200 200 R, 5%, 1/4 W, Carbon Film 19 1 R3 11 k 11 k, 5%, 1/8 W, Carbon Film 20 1 R4 10 10 R, 5%, 1/4 W, Carbon Film 21 1 R5 150 150 R, 5%, 1/8 W, Carbon Film HS 1000 V, 1 A, Rectifier, DO-41 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 HEATSINK Custom Ferrite Bead 3.5 mm x 7.6 mm, 75 Ohms at 25 MHz, 22 AWG hole, Ferrite Bead 1 mH 1 mH, 0.15 A, Ferrite Core NPN, Small Signal BJT, 40 V, 0.2 A, TO-92 PNP, Small Signal BJT, 40 V, 0.2 A, TO-92 200 k, 5%, 1/2 W, Carbon Film 22 1 R6 10 k 10 k, 5%, 1/8 W, Carbon Film 23 1 R7 10 10 R, 5%, 1/8 W, Carbon Film 24 1 R8 0.33 25 2 R9 R11 1k 1 k, 5%, 1/8 W, Carbon Film 26 1 R10 470 470 R, 5%, 1/8 W, Carbon Film 0.33 R, 1%, 1/2 W 27 1 R12 1.6 k 1.6 k, 5%, 1/8 W, Carbon Film 28 1 R13 200 200 R, 5%, 1/8 W, Carbon Film 29 1 RF1 8.2 30 1 T1 EE16 31 1 U1 TNY274P 32 1 U2 PC817A 33 1 VR1 Page 8 of 25 8.2 R, 2.5 W, Fusible/Flame Proof Wire Wound Bobbin, EE16, Horizontal, 10 pins TinySwitch-III, TNY274P, DIP-8C Opto coupler, 35 V, CTR 80-160%, 4-DIP BZX79-B4V3 4.3 V, 500 mW, 2%, DO-35 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 7 Transformer Specification 7.1 Electrical Diagram 4 W1 Bias 5 10 NC W4 +5V NC 8 W3 Balance Winding 1 2 W2 Primary 3 Figure 4 – Transformer Electrical Diagram. Copper Foil Wrapped in Tape Starting lead to be connected to pin 1 Figure 5 – Copper Foil preparation for winding 3. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 60 second, 60 Hz, from Pins 1-5 to Pins 6-10 Pins 2-3, all other windings open, measured at 132 kHz. Pins 2-3, all other windings open Pins 2-3, with Pins 8-10 shorted, measured at 132 kHz. 3000 VAC 2519µH, -0/+12% 733 kHz (Min.) 65µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] [8] Description Core: EE16 Gapped for 174 nH/T^2 Bobbin: EE16 Horizontal 10 Pins Magnet Wire: 34 AWG Triple Insulated Wire: 26 AWG Copper Foil 0.06 mm tick, 7.6mm wide Tape, 8.6 mm Wide Tape, 12 mm Wide Varnish Page 9 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 7.4 5 W Charger for Portable Audio Player July 19, 2006 Transformer Build Diagram Tape 8 10 6T # 26 TIW X 2 W4 Tape W3 1.5T Copper Foil 1 Tape 2 40 T #34 AWG W2 Tape 40 T #34 AWG Tape Tape W1 3 40 T #34 AWG 5 4 20T # 34 AWG X 2 10T 10T Figure 6 – Transformer Build Diagram. 7.5 Transformer Construction Bobbin Preparation W1 Bias Winding + Core Cancellation Basic Insulation W2 Primary Basic Insulation Place the bobbin [2] on the winding machine with the primary pin side oriented to the left hand side. Start at Pin 4. Wind 10 bifilar turns of item [3] from left to right. Take the lead out of the winding area and terminate it at pin 5. Bring the lead back to the winding area and continue winding on the same layer. Wind 10 more turns. The whole layer must be uniformly and tightly wound. Cut the finishing lead just at the end of the winding. Use two layers of item [6] for basic insulation. Start at Pin 3. Wind 40 turns of item [3] from left to right in 1 layer. Use one layers of item [6] for basic insulation. Continue winding on a second layer. Wind 40 turns from right to left. Use one layers of item [6] for basic insulation. Wind 40 more from left to right on a third layer. Terminate on pin 2. The three layers should be uniformly and tightly wound. Use one layers of item [6] for basic insulation. Prepare winding as shown in figure 5 using items [5] and [7]. Very W3, Balance Winding important. For this winding reverse the winding direction of the machine. Start at pin 1, Wind 1.5 turns of copper foil. Finish lead is Basic Insulation W4 Secondary Winding Outer Wrap Final Assembly left unconnected. Use one layer of item [6] for basic insulation. Start at Pins 10. Wind 6 bifilar turns of item [4] Spread turns evenly across bobbin. Finish on Pin 8. Wrap windings with 3 layers of tape item [6]. Assemble and secure core halves. Varnish impregnate using item [8]. Page 10 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 8 Transformer Spreadsheets ACDC_TinySwitchIII_031006; Rev.1.11; Copyright Power Integrations 2006 INPUT INFO ACDC_TinySwitch-III_031006_Rev1-11.xls; TinySwitch-III Continuous/Discontinuous Flyback OUTPUT UNIT Transformer Design Spreadsheet ENTER APPLICATION VARIABLES Customer VACMIN 85 Volts Minimum AC Input Voltage VACMAX 265 Volts Maximum AC Input Voltage fL 50 VO 5.33 IO 1.00 Hertz AC Mains Frequency Volts Output Voltage (at continuous power) Power Supply Output Current (corresponding to peak Amps power) Power n 0.68 Z 0.81 tC 3.00 CIN 5.33 Watts Continuous Output Power Efficiency Estimate at output terminals. Under 0.7 if no better data available Z Factor. Ratio of secondary side losses to the total losses in the power supply. Use 0.5 if no better data available mSec onds Bridge Rectifier Conduction Time Estimate uFara 13.6 ds Input Capacitance 13.60 ENTER TinySwitch-III VARIABLES TinySwitch-III Auto Chosen Device Chose Configuration TNY274 Recommended TinySwitch-III Standard Current Limit Enter "RED" for reduced current limit (sealed adapters), "STD" for standard current limit or "INC" for increased current limit (peak or higher power applications) TNY274 STD ILIMITMIN 0.233 Amps Minimum Current Limit ILIMITTYP 0.250 Amps ILIMITMAX 0.267 Amps Maximum Current Limit fSmin 124000 Hertz Minimum Device Switching Frequency I^2fmin VOR 117.00 VDS VD A^2k I^2f (product of current limit squared and 7.425 Hz frequency is trimmed for tighter tolerance) Reflected Output Voltage (VOR < 135 V 117 Volts Recommended) 10 Volts TinySwitch-III on-state Drain to Source Voltage 0.50 0.5 Volts Output Winding Diode Forward Voltage Drop KP 0.65 KP_TRANSIENT 0.40 Page 11 of 25 Ripple to Peak Current Ratio (KP < 6) Transient Ripple to Peak Current Ratio. Ensure KP_TRANSIENT > 0.25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 ENTER BIAS WINDING VARIABLES VB 22.00 Volts VDB Bias Winding Voltage 0.70 Volts NB 22.64 Bias Winding Number of Turns VZOV 28.00 Volts Over Voltage Protection zener diode voltage. UVLO VARIABLES V_UV_TARGET 87.87 Volts V_UV_ACTUAL 84.70 Volts Target DC under-voltage threshold, above which the power supply with start Typical DC start-up voltage based on standard value of RUV_ACTUAL RUV_IDEAL 3.43 Mohms Calculated value for UV Lockout resistor RUV_ACTUAL 3.30 Mohms Closest standard value of resistor to RUV_IDEAL ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE16 EE16 Core Enter Transformer Core EE16 EE16_B OBBIN Bobbin P/N: PC40EE16-Z P/N: EE16_BOBBIN AE 0.192 cm^2 LE 3.5 cm AL Core Effective Path Length 1140 nH/T^2 Ungapped Core Effective Inductance BW 8.6 mm M L NS Core Effective Cross Sectional Area 6 0 mm Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) 3 Number of Primary Layers 6 Number of Secondary Turns DC INPUT VOLTAGE PARAMETERS VMIN 80 Volts Minimum DC Input Voltage VMAX 375 Volts Maximum DC Input Voltage CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.63 Duty Ratio at full load, minimum primary inductance and minimum input voltage IAVG 0.11 Amps Average Primary Current IP 0.23 Amps Minimum Peak Primary Current IR 0.15 Amps Primary Ripple Current IRMS 0.15 Amps Primary RMS Current Page 12 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP_TOLERANCE 2519 uHenries 12 % Typical Primary Inductance. +/- 12% to ensure a minimum primary inductance of 2249 uH Primary inductance tolerance NP 120 Primary Winding Number of Turns ALG 174 nH/T^2 Gapped Core Effective Inductance BM 2909 Gauss BAC 952 Gauss Maximum Operating Flux Density, BM<3000 is recommended AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) ur 1654 Relative Permeability of Ungapped Core LG 0.12 mm Gap Length (Lg > 0.1 mm) BWE 25.8 mm Effective Bobbin Width OD 0.21 mm Maximum Primary Wire Diameter including insulation INS 0.04 mm Estimated Total Insulation Thickness (= 2 * film thickness) DIA 0.17 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) AWG CM CMA 34 AWG 40 Cmils 273 Cmils/Amp Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < 500) TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP 4.68 Amps Peak Secondary Current ISRMS 2.29 Amps Secondary RMS Current IRIPPLE 2.06 Amps Output Capacitor RMS Ripple Current CMS 458 Cmils Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) AWGS 23 AWG VOLTAGE STRESS PARAMETERS VDRAIN PIVS Page 13 of 25 640 Volts 24 Volts Maximum Drain Voltage Estimate (Assumes 20% zener clamp tolerance and an additional 10% temperature tolerance) Output Rectifier Maximum Peak Inverse Voltage Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency. Efficiency measurements were done at the end of the cable on the load side. 9.1 Efficiency EFFICIENCY Vs LINE VOLTAGE 80 Output Efficiency (%) 70 60 50 40 30 IOUT=0.95A 20 10 0 80 100 120 140 160 180 200 220 240 260 280 Line Voltage (AC) Figure 7 – Efficiency vs. Input Voltage, Room Temperature, 60 Hz. EFFICIENCY Vs LOAD 80 Output Efficiency (%) 70 60 50 40 115VAC 230VAC 30 20 10 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 Output Current (A) Figure 8 – Efficiency Vs Load. Page 14 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 9.1.1 Active Mode CEC Measurement Data All single output adapters, including those provided with products, for sale in California after Jan 1st, 2007 must meet the California Energy Commission (CEC) requirement for minimum active mode efficiency and no load input power. Minimum active mode efficiency is defined as the average efficiency of 25, 50, 75 and 100% of rated output power with the limit based on the nameplate output power: 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 single input voltage only then the measurement is made at the rated single nominal input voltage (115 VAC or 230 VAC), for universal input adapters the measurement is made at both nominal input voltages (115 VAC and 230 VAC). To meet the standard the measured average efficiency (or efficiencies for universal input supplies) must be greater than or equal to the efficiency specified by the CEC/Energy Star standard. Percent of Full Load 25 50 75 100 Average CEC specified minimum average efficiency (%) Efficiency (%) 115 VAC 230 VAC 72.63 73.31 72.08 69.25 71.82 69.55 73.25 72.5 70.80 71.52 63.48 More states within the USA and other countries are adopting this standard, for the latest up to date information please visit the PI Green Room: http://www.powerint.com/greenroom/regulations.htm Page 15 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 9.2 5 W Charger for Portable Audio Player July 19, 2006 No-load Input Power NO LOAD POWER CONSUMPTION 450 400 Input Power (mW) 350 300 250 200 CEC LIMIT INPUT POWER 150 100 50 0 80 100 120 140 160 180 200 220 240 260 280 Line Voltage (AC) Figure 9 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. Note: CEC limit is actually 500 mW, not 400 mW as shown in figure above. 9.3 Regulation 9.3.1 Output Characteristic. Measurements were done at the end of the cable on the load side. OUTPUT CHARACTERISTIC 6 Output Voltage 5 4 3 115VAC 230VAC 2 1 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 Output Current (A) Figure 10 – Output Characteristic. Page 16 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 10 Thermal Performance When doing this test, the unit was put inside of a cardboard box. The box was put inside a thermal chamber. No free air was flowing around the unit. Item Page 17 of 25 Temperature (°C) 85 VAC 265 VAC Ambient 50 50 TinySwitch (U1) 93 83 Transformer (T1) 81 84 Output Rectifier (D7) 88 90 Output Capacitor (C7) 77 78 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 11 Waveforms 11.1 Drain Voltage and Current, Normal Operation Figure 11 – 85 VAC, Full Load. Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 100 V, 2 µs / div Figure 12 – 265 VAC, Full Load Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 200 V / 2 µs /div 11.2 Output Voltage Start-up Profile Figure 13 – Start-up Profile, 115VAC 1 V, 2 ms / div. Page 18 of 25 Figure 14 – Start-up Profile, 230 VAC 1 V, 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 11.3 Drain Voltage and Current Start-up Profile Figure 15 – 85 VAC Input and Maximum Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 100 V & 2 ms / div. Page 19 of 25 Figure 16 – 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 200 V & 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 11.4 Load Transient Response (75% to 100% Load Step) In the figures shown below, signal averaging was used to better enable viewing the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response. Figure 17 – Transient Response, 115 VAC, 75-10075% Load Step. Top: Load Current, 0.5 A/div. Bottom: Output Voltage 200 mV, 0.5 ms / div. Page 20 of 25 Figure 18 – Transient Response, 230 VAC, 75-10075% Load Step Upper: Load Current, 0.5 A/ div. Bottom: Output Voltage 200 mV, 0.5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 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 Figures 19 and 20. 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 19 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 20 – Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added) Page 21 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 11.5.2 Measurement Results Ripple measurements were done at the end of the cable on the load side. Figure 21 – Ripple, 85 VAC, Full Load. 50 uS, 100 mV / div Figure 22 – 5 V Ripple, 115 VAC, Full Load. 50 uS, 100 mV / div Figure 23 – Ripple, 230 VAC, Full Load. 50 uS, 100 mV / div Page 22 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 12 Conducted EMI Figure 24 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits. Bolt Traces With OUTRETURN connected to ARTHAND, Light traces With OUTRETURN connected to GND Figure 25 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits. Bolt traces with OUTRETURN CONNECTED TO GND. Light Traces with OUTRET Connected to ARTHAND Page 23 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 13 Revision History Date November 20, 2005 July 19, 2006 Page 24 of 25 Author VC PV Revision 1.0 1.1 Description & changes Initial release Edits and corrections Reviewed JC / VC KM Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-113 5 W Charger for Portable Audio Player July 19, 2006 For the latest updates, visit our website: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2006 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] GERMANY Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3910 Fax: +49-89-5527-3920 e-mail: [email protected] JAPAN Keihin Tatemono 1st Bldg 2-12-20 Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa ken, Japan 222-0033 Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN 5F, No. 318, Nei Hu Rd., Sec. 1 Nei Hu Dist. Taipei, Taiwan 114, R.O.C. Phone: +886-2-2659-4570 Fax: +886-2-2659-4550 e-mail: [email protected] CHINA (SHANGHAI) Rm 807-808A, Pacheer Commercial Centre, 555 Nanjing Rd. 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