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Design Example Report
Title Specification Application Author Document Number Date Revision 2.25W Power Supply using LNK520P Input: 90 - 265 Vac Output: 4.5V / 0.5A Portable CD player with AM/FM Radio Power Integrations Applications Department DER-42 November 18, 2004 1.0
Summary and Features * * * * * * * Very low No Load Input Power - less than 80 mW @ 100 Vac. Low RFI allows good AM radio reception with very little interference Meets EMI, EN55022 B with no Y1 capacitor. Good voltage regulation with no optocoupler Lightweight solution for portable applications Ideal replacement for linear adapters Average efficiency @ 120 VAC greater than 70%
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-42
Portable CD Player - LNK520P
November 18, 2004
Table Of Contents
1 2 3 4 Introduction .................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic ...................................................................................................................5 Circuit Description.......................................................................................................6 4.1 Input EMI Filtering................................................................................................6 4.2 LinkSwitch Primary ..............................................................................................6 4.3 Output Rectification .............................................................................................6 5 PCB Layout.................................................................................................................7 6 Bill Of Materials...........................................................................................................8 7 Transformer Specification ...........................................................................................9 7.1 Transformer Winding ...........................................................................................9 7.1.1 Electrical Specifications................................................................................9 8 Transformer Spreadsheet .........................................................................................10 9 Performance Data.....................................................................................................12 9.1 Efficiency ...........................................................................................................12 9.2 No-load Input Power ..........................................................................................13 9.3 Output Voltage Regulation.................................................................................13 9.4 Output Ripple Measurements ............................................................................14 9.4.1 Ripple Measurement Technique.................................................................14 10 AM Radio Reception Test .....................................................................................15 11 Conducted EMI .....................................................................................................16 12 Revision History ....................................................................................................18
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. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
Page 2 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
1 Introduction
This document is an engineering report describing a prototype Flyback power supply utilizing LNK520P. The LNK520P is chosen for its superior low noise properties and low system cost. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
Figure 1 - LNK520P Power Supply 4.5V 0.5A - Top View
Figure 2 - LNK520P Power Supply 4.5V 0.5A - Bottom View
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DER-42
Portable CD Player - LNK520P
November 18, 2004
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power No Load Input Power Efficiency Environmental Conducted EMI Safety Surge Ambient Temperature TAMB 0 Symbol VIN fLINE Min 90 47 Typ Max 265 64 0.3 5.4 9.5 Units VAC Hz W V V mV mA Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1
2.7
4.5 200 500
At No Load (RMS), 20 MHz Bandwidth
POUT PNoLoad
2.25 100 50
W mW %
@ 100 Vac Input
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
1.5 50
kV
o
1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: 12 Free convection, sea level
C
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DER-42
Portable CD Player - LNK520P
November 18, 2004
3 Schematic
Figure 3 - LNK520P based Flyback Converter Schematic
Page 5 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
4 Circuit Description
LinkSwitch LNK520P is used in a Flyback converter shown in Figure 3 to obtain 4.5V, 0.5A output from 90-265 Vac input. The bias winding output voltage is used provide primary side feedback to LinkSwitch. Therefore, the bias winding is wound over the secondary winding to obtain very good regulation. Special construction methods are used for the transformer to obtain low No-Load input power, and at the same time to pass EMI testing and have good AM (530 kHz - 1.6 MHz) reception quality. 4.1 Input EMI Filtering
Fusible resistor RF1 acts as fuse and also limits inrush current during power ON of the power supply. Bridge diodes D1, D3, D5, D6 rectify AC voltage into DC voltage and charges capacitors C3 and C4. Inductor L1, Ferrite bead L2, and capacitors C3 and C4 form a filter and attenuate EMI noise. 4.2 LinkSwitch Primary
This design uses RCD (C1, D4, R1, and R2) clamping across primary winding to limit the drain voltage below 700V, when the MOSFET inside U1 turns OFF. The capacitor C5 connected to C (control) pin of U1 stores energy and provide power to the internal circuit of U1 and also to turn ON the U1's Mosfet, during power-up and steady state operation. C6, D7, and R4 form bias supply components, which provide feedback current to the Control pin during steady state operation. The bias winding voltage is designed for about 6.4V to keep the No-Load input power to minimum. 4.3 Output Rectification
When U1 Mosfet is turned ON, current flows through transformer primary and stores energy. When U1 is ON, output diode D2 is OFF. When the U1 Mosfet is OFF, D2 is forward biased, and the stored energy is transferred to the secondary and stores in C2. The snubber C7 and R5 across D2 will slow down D2 switching and improve EMI. L3 and C8 form post filter to reduce output ripple voltage and also attenuate EMI noise.
Page 6 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
5 PCB Layout
Figure 4 - PCB Layout
Page 7 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
6 Bill Of Materials
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 1 1 1 1 1 1 1 1 1 Qty. 1 1 2 1 1 1 1 4 1 1 1 Reference C1 C2 C3, C4 C5 C6 C7 C8 D1, D3, D5, D6 D2 D4 D7 JP1 L1 L2, L3 OC1 PCB1 RF1 R1 R2 R4 R5 T1 U1 Part Description 470 pF, 1 KV, Ceramic capacitor, Z5U 470 F, 10V, AL Electrolytic Low ESR capacitor 4.7 F, 400V, AL Electrolytic capacitor 0.22 F, 25V, Ceramic capacitor, X7R 10 F, 50V, AL Electrolytic capacitor 470 pF, 100V, Ceramic capacitor, NPO 100 F, 10V, AL Electrolytic capacitor General purpose Diode, 1A, 1KV Schottky diode, 1A, 40V Glass passivated diode 1A, 1KV Switching diode, 200 mA, 200V Jumper wire # 26 AWG Ferrite core inductor, 1 mH Large Ferrite Bead Output cable 6 foot, # 22 AWG, 2-wire PCB Fusible resistor, 8.2 , 1W Resistor, 300 K, 1/4W, 5% Resistor, 200 , 1/4W, 5% Resistor, 226 , 1/4 W, 1% Resistor, 20 , 1/4 W, 5% EE16 core custom transformer LinkSwitch P/N 1N4007 1N5819 1N4007G BAV20 SBCP47HY102B 2761008112 custom custom custom LNK520P Mfg. Any Any Any Any Any Any Any Any Any Any Any Any Tokin Fair-rite Any Any Any Any Any Any Any Any Power Integrations
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DER-42
Portable CD Player - LNK520P
November 18, 2004
7 Transformer Specification
7.1 Transformer Winding
2 W2,Primary, 104T,#36 3 7 W4,Secondary, 7T,#28x2(TIW) 6 4 W5,Bias Wndg, 9T,#35 5
Figure 5 - Transformer Winding
7.1.1 Electrical Specifications
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 1 second, 60 Hz, from Pins 1- 5 to Pins 6-7. Pins 2-3, all other windings open, measured at 42 kHz, 0.4 VRMS Pins 2-3, all other windings open Pins 2-3, with all other pins shorted, measured at 132 kHz, 0.4 VRMS 3000 VAC 2.51 mH - 2.64 mH - 2.77 mH 300 kHz (Min.) 83 H (Max.)
Page 9 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
8 Transformer Spreadsheet
Parameters INPUT INFO OUTPUT UNIT Description ENTER APPLICATION VARIABLES VACMIN VACMAX fL VO IO VBIAS tC CIN 90 265 50 4.5 0.633 21 3 9.4 msec uFarads Volts Volts Hertz Volts Amps Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Specified Nominal Output current Bias voltage (recommended default 20V, minimum 16V) Bridge Rectifier Conduction Time Estimate Input Filter Capacitor
TARGETED / ESTIMATED LOSSES P_NO_LOAD_GOAL PCORE RCLAMP CTRF ESR RSEC 300 60 0.15 0.02 300 mW 239.4 mW 300.0 Kohm 60.0 pF 0.150 Ohms 0.02 Ohms Target No Load losses for Power supply Estimated Core Losses at peak Flux Density (BP) Primary clamp resistor (recommended default clamp resistor, RCLAMP) Transformer primary capacitance Output Capacitor ESR at 50C Estimated Resistance of transformer secondary winding. Estimated power losses at no load (includes feedback, switching and primary clamp losses, but not preload resistor or secondary snubber). No Load losses target achieved.
P_NO_LOAD_LOSS
273 mW
DC INPUT VOLTAGE PARAMETERS VMIN VMAX 104 Volts 375 Volts Minimum DC Input Voltage Maximum DC Input Voltage
ENTER OUTPUT CABLE PARAMETERS RCABLE VCABLE ENTER LinkSWITCH & OUTPUT DIODE VARIABLES LinkSwitch LNK520 Power I^2 f VOR VLEAK VD VR 76 0 0.5 2710 A^2 Hz 76.00 Volts 0.00 Volts 0.5 Volts 60 Volts Universal 5.5 115 Doubled/230 3.5 I^2 f (typical) co-efficient for LinkSwitch Reflected Output Voltage (40Page 10 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
Rated Average Forward current for secondary diode
ID
3
Amps
DISCONTINUOUS MODE CHECK KDP TON TDON 1.93 6.83 us 8.82 us Ensure KDP > 1.15 to for discontinuous mode operation. Linkswitch conduction time Secondary Diode conduction time
VOLTAGE STRESS ON LinkSWITCH AND OUTPUT DIODE VDRAIN PIVS 554 Volts 29.7 Volts Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Reverse Voltage
CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IRMS 0.29 0.036 Amps 0.079 Amps Maximum Operating Duty Cycle Average Primary Current Primary RMS Current
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type Core Bobbin AE LE AL VE BW KCORE T(n) M NS 7 0.96 7.8 ee16 PC40EE16Z BE-16-116CP 0.192 cm^2 3.5 cm 1140 nH/T^2 672 mm^3 7.8 mm 602 kW/m^3 0.9600 0 mm Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Effective Core Volume Bobbin Physical Winding Width Core losses per unit volume Estimated transformer efficiency. T(n)=(PSCU+PCORE/2)/POEFF. Re-iterate with n = 0.9543 Safety Margin Width Number of Secondary Turns
TRANSFORMER PRIMARY DESIGN PARAMETERS dLP LP L LBIAS NP NB ALG BP LG 2 0.6 1.0000 1.000 2638 uHenries 2 0.6 104 29 244 nH/T^2 3699 Gauss 0.08 mm Gapped Core Effective Inductance Peak Flux Density (BP<3700) Consult your transformer vendor for Gaps less than 0.08mm Consider film gapping Primary Winding Number of Turns Constant to account for reduction of inductance at higher flux densities. (0.999Page 11 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
Maximum Primary Wire Diameter including insulation to give specified number of layers.
OD DIA AWG CMA AWG_BIAS
0.15 mm 0.12 mm
Bare conductor diameter Primary Wire Gauge (Rounded to next smaller 37 AWG standard AWG value) Primary Winding Current Capacity (200 < CMA < 257 Cmils/Amp 500) 35 AWG
TRANSFORMER SECONDARY DESIGN PARAMETERS ISP ISRMS IRIPPLE AWGS DIAS ODS INSS VSEC 3.77 Amps 1.33 Amps 1.17 Amps 29 AWG 0.29 mm 1.11 mm 0.41 mm 0.013 Volts Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Insulated Wire Outside Diameter Maximum Secondary Insulation Wall Thickness Voltage Drop across secondary winding
9 Performance Data
All measurements are performed at room temperature, 60 Hz input frequency, unless otherwise specified. The output voltage is measured at the end of a 6-foot # 22 AWG cable with 0.2 total resistance. 9.1 Efficiency
80.00
70.00 Efficiency (%)
60.00 Vin = 90 Vac Vin = 120 Vac 50.00 Vin = 220 Vac Vin = 265 Vac 40.00 0 100 200 300 400 500 600 700 Output Current (A)
Figure 6 - Efficiency versus Output Current
Page 12 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
9.2
No-load Input Power
150 Input Power (mW) 130 110 90 70 50 80 110 140 170 200 230 260 290 Input Voltage (Vac) No Load
Figure 7 - No-Load Input Power versus Input Voltage
9.3
Output Voltage Regulation
7 6 Output Voltage (V) 5 4 3 2 1 0 0 100 200 300 400 500 600 700 Output Current (A) Vin = 90 Vac Vin = 265 Vac
Figure 8 - Output Voltage versus Output Current
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DER-42 9.4
Portable CD Player - LNK520P
November 18, 2004
Output Ripple Measurements
9.4.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 9 and Figure 10. The 5125BA 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) 1.0 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 9 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 10 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
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DER-42
Portable CD Player - LNK520P
November 18, 2004
Figure 11 - Output Voltage Ripple (worst case) 120 Vac, 4.47 V, 0.5A
10 AM Radio Reception Test
The adapter is tested with a portable CD player with TV/ Weather/ AM/ FM features, for AM radio reception quality. The tested frequencies are 680 KHz, 810 KHz, and 1170 KHz. The reception is good as compared to operating with batteries. There is either very little or no additional noise at all when tuning to a very weak radio signal and operating in close proximity to the adapter.
Page 15 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
11 Conducted EMI
The EMI conducted emission tests (EN55022 B) are done at 120 Vac and 220 Vac, 0.5A load, and Neutral (worst case).
Figure 12 - Conducted EMI, EN55022 B, 120 Vac, output return connected to artificial hand
Figure 13 - Conducted EMI, EN55022 B, 120 Vac, output return floating
Page 16 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
Figure 14 - Conducted EMI, EN55022 B, 220 Vac, output return connected to artificial hand
Figure 15 - Conducted EMI, EN55022 B, 220 Vac, output return floating
Page 17 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
12 Revision History
Date November 18, 2004 Author MJ Revision 1.0 Description & changes Initial release Reviewed VC / AM
Page 18 of 19
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DER-42
Portable CD Player - LNK520P
November 18, 2004
For the latest updates, visit our Web site: 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, nor does it convey any license under its patent rights or the rights of others.
PATENT INFORMATION 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.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
WORLD HEADQUARTERS Power Integrations 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: usasales@powerint.com AMERICAS Power Integrations, Inc. 4335 South Lee Street, Suite G, Buford, GA 30518, USA Phone: +1-678-714-6033 Fax: +1-678-714-6012 e-mail: usasales@powerint.com
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