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title engineering prototype report for ep-5 4 ? 2.75 w charger/adapter using lnk520p (linkswitch) specification 85-265 vac input, 5.5 v, 500 ma, 2.75 w output application low cost charger / adapter author power integrati ons applicati ons department document number EPR-54 date 07-may-2004 revisio n 1.1 summar y and features ? low cost, lo w compone nt count bat tery charger/adapter ? replaces line ar transformer based solut i ons ? optimized switching ch aracteristics and low-side configur ation of lnk520 minimizes emi - achieves greater than 10 dbv margin t o composite conducte d limits - no y1 safety capacitor r equired for emi complia nce - ultra-low earth leakage current, <5 a ? small low cost ee16 transformer - provision for ee13 transformer for smaller size ? approximat e constant voltage, c onstant cur r ent (cv/cc) primary sensed output characterist ic ? efficiency gr eater than 6 5 % across a ll line/ load conditions po w e r integrations 5245 hellyer avenue, san jo se, ca 951 38 usa. tel: +1 408 4 14 920 0 fax: +1 408 41 4 9201 ww w.po we rin t.com t he products and app licati ons il lustrate d herei n (i nclu din g circu i ts ext e rna l to th e pro ducts a nd transform e r constructio n ) ma y b e cover ed b y on e or more u.s. and foreign p a tent s or potentia ll y b y pe nd ing u . s. and foreig n patent ap plic ations assi gne d to po w e r inte gratio ns. a c o mp l e te l i st of po w e r integr ations ? p a tents ma y b e fo un d at ww w.pow erint.com .
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 table of contents 1 introducti on ................................................................................................................. 4 2 power supply s pecificat ion ........................................................................................ 5 3 schemat ic ................................................................................................................... 6 4 circuit desc ription ...................................................................................................... 7 4.1 input emi f iltering ............................................................................................... 7 4.2 linkswitch primary and out put f eedbac k ........................................................... 7 4.3 output rectif ication ............................................................................................. 9 5 pcb lay out ................................................................................................................ 9 6 bill of ma te rials ........................................................................................................ 10 7 transforme r spec ificatio n ......................................................................................... 11 7.1 electrical diagram ............................................................................................. 11 7.2 electrical spec ifications ..................................................................................... 11 7.3 material s ............................................................................................................ 12 7.4 transforme r build diagram ............................................................................... 13 7.5 transforme r cons tructi on .................................................................................. 15 7.6 transforme r bobbing drawing ........................................................................... 16 8 performanc e data .................................................................................................... 17 8.1 efficienc y ........................................................................................................... 17 8.2 no-load input power .......................................................................................... 18 8.3 regulati on ......................................................................................................... 19 8.3.1 line and l oad ............................................................................................ 19 8.4 thermal perf ormance ........................................................................................ 20 9 wavefo rms ............................................................................................................... 22 9.1 drain voltage and cur r ent, normal oper ation ................................................... 22 9.2 output voltage start-u p profile (ba ttery load) .................................................. 22 9.3 drain voltage and cur r ent start-u p profile ........................................................ 23 9.4 load transient response ( 75% to 100% load step) ....................................... 24 9.5 output ripple m easurement s ............................................................................ 25 9.5.1 ripple measurement t e chnique ................................................................ 25 9.5.2 ripp l e measurement result s ..................................................................... 26 10 conducted emi ..................................................................................................... 27 11 appendix a: ee16 simp le constr uction ................................................................ 29 11.1 introducti on ........................................................................................................ 29 11.2 schemat ic .......................................................................................................... 29 11.3 bill of ma te rials .................................................................................................. 29 11.4 transforme r spec ificatio n .................................................................................. 31 11.4.1 transforme r winding .................................................................................. 31 11.4.2 electrical spec ifications .............................................................................. 31 11.4.3 transforme r build diagram ........................................................................ 32 11.5 performanc e data ............................................................................................. 32 11.5.1 efficienc y .................................................................................................... 33 11.5.2 line and load r egulati on .......................................................................... 34 11.6 conducted em i .................................................................................................. 34 12 revision hist ory ................................................................................................ 36 page 2 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter important note: although this board is designed to satisfy safe ty isolation requirem ents, the engineering prototype has not been agency approved. ther efore, all testing should be per formed using an is olation transforme r to provide the ac input to the prototype board. page 3 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 1 introduct i on this document is an engineer ing report describin g a 5.5 v, 500 ma c h arger/adapter power sup p ly. the p o wer supply utilizes t he link switch lnk520 device, optimized for bias winding feedback . the link switch integrates a 700 v mosfet, pwm controller, start-up, thermal shut- down, and fault protection circuitry. this p o wer supp ly is a cost effective replacement of linear transformer based power supplies with the additio n al features of universal input range and high energy efficiency. compared to the lnk500, the optimized switching characte ristics of the lnk520 and th e low-side configuration prov ides improved emi performance and less variation in emi performance from design to design. the document contains the power supply spec ific ation, schematic, bill of materials, transformer documentation, printed ci rcuit layout, and performance data. f i gure 1 ? populated circuit board photograph. an alternat e desig n ut iliz ing s i mp lified ee1 6 tr ansformer construction is pres ented. se e appendix a for schematic, construction details and performance curves. page 4 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 2 power supply s p ecificatio n des c ription sy mbol min ty p max units c o mment input voltage v in 8 5 2 6 5 v a c 2 wire ? no pro t e c tive ground. freq uen cy f line 4 7 5 0 / 6 0 6 4 h z no-l oad inp u t power 0.3 w measured at 23 0 vac + 10% outpu t output voltag e v out 5 . 0 5 . 5 6 v ? ?
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 note: ep-54 is designed for a battery load. if a resistive or electronic load is used the supply may fail to start up at full load. this is normal. to ensure startup into a resistiv e load, increase the value of c5 to 1
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 4 circuit descriptio n the circuit schematic shown in f i gure 3 s h ows a d e sign that provides a cons tant voltage / constant current (cv/cc) output characterist ic from a univ e rsal i nput v o ltage range of 85 vac-265 vac. this des ign delivers 2.75 w with nominal peak power point voltage of 5.5 v and a current of 500 ma. the overall operating envelope is shown in figure 10. the unit provides a cc operating range of
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 when power is applied, high voltage dc appears at the drain pin of linkswitch (u1). the cont rol pin capacitor c5 is then char ged through a switche d high v o lt age current source connected internally between t he drain and cont rol pins. when the control pin reaches approximately 5.6 v rela tive to the source pin, the interna l current source is turned off. the internal cont rol circuitry is activa ted and the high voltage mosfet starts to switch, using t he energy in c5 to power the ic. once the output has reached r egulation, pwm control maintains cv r e gulation by indirectly s ensing the output winding v o ltage. i deally the dc output vo ltage is equal t o the bias v o ltage plus t he forward drop of d6b multiplied by the transformer secondary winding to bias winding turns r a tio minus t he forwar d drop of d7. however, leakage inductance causes errors that vary with load, causing the output voltage to rise at no- load. to give the bes t regulation, the bias and secondary winding s should be physically close to each other in the transformer. diode d6b rectifies the output of the bias winding, whic h is then smoothed by c3 to provide a dc voltage t o be fed to the control pi n via r4. resistor r3 is added to filter noise due to leakage inductance. the value of r4 is set such that, at the peak power point, whe r e the output is still in cv r egulation, the control pin current is approximately 2.2 ma. as the output load is increased, the peak power point (defined by 0.5 l i 2 f ) is exceeded. the out put voltage and ther efore primary side bias voltage reduce. the reduction in the bias voltage results in a proportional r eduction of control pin current, which lowe rs the internal link switch current limit (current limit control). constant current (cc) operat ion controls secondary-side out put current by reducing the primary-side current limit. the current limit reduction c haracte ristic has been optimized to maintain an approxim ate constant output curr ent as the output voltage and bias voltage is reduced. if the load is increased further and the cont rol pin current fal l s below approximately 0.8 ma, the cont rol pin capa citor c5 will dischar ge and li nks w i t ch will enter auto- restart operation. current limit control removes the need for any secondar y-side cur r ent sensing component s (sense resistor, transistor, optocoupler and ass o ciated components). removing the secondary sense circuit dramat ically improves efficiency, giving the associated benefit of r educed enclosure siz e . diode d5, c4, r1, and r2 form the primary clamp net work. this limits the peak drai n voltage due to leakage inductanc e. res i stor r2 allows t he use of a s l ow, low cost rectifier diode by limiting the reverse current through d5 when u1 turns on. the selection of a slow diode improv es radiated emi and also improv es cv regulation, esp e cially at no load. page 8 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 4.3 output rectification output rectification is prov ided by schottky diode d7. the low forward voltage provide s high efficiency across the operating range. low esr capacitor c6 achiev es minimum output ripple and maximizes operating efficiency. 5 pcb la yout figure 4 ? ep-54 printe d circuit board layout and dimensi o n s (0. 001 in che s ) (note: c7, r5 and r6 a r e n o t populate d ). page 9 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 6 bill of materials item qt y referen ce des c ription (t y p e) p/n, t y pe manufac ture r 1 1 u 1 linksw itch lnk5 2 0 p p o w e r integr ati o n s 2 2 c 1 , c 2 4.7 ? ? ? ? ? ?
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 7 t r ansformer s p ecification note: to correctly center the output volt age over a junction temperature of 25
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 7.3 m a t e rials i t e m d e s c r i p t i o n [1] core: ee16, pc40ee16 t d k ? a lg 252 nh/t 2 [2] bobbin: ho ri zontal 10 pin (see se ction 7 . 6) [3] magnet wire: #32 awg, please se e not e on next pag e [4] foil: tape wrappe d co ppe r foil, 7. 5 mm +/-0 .1 mm wide by 0.05 mm/2 mil thick, 35 mm +/- 0.5 mm le ngth ? se e ad ditional drawi ng [5] triple in sulat ed wire: #30 awg [6] magnet wire: #31 awg, please se e not e on next pag e [7] tape: 3m 12 98 polyeste r film (white ) 3 22 mils (8.2 mm) wid e by 2.2 mils thick [8] tape: 3m 12 98 polyeste r film (white ) 2 91 mils (7.4 mm) wid e by 2.2 mils thick [9] tape: 3m 12 98 polyeste r film (white ) 5 86 mils (14.9 mm) wid e by 2.2 mils thick [10 ] tape: 3m 12 98 polyeste r film (white ) 1 96 mils (5.0 mm) wid e by 2.2 mils thick [11 ] barrie r tap e : 2.0 mm wide, 0.15 mm thic k, please see the note on the next page [12 ] barrie r tap e : 2.25 mm wid e , 0.15 mm thick, plea se see the note o n the next page [13 ] glue av118 note: the transformer is an integral p a rt of the emi performance of this design. changes to the transformer, even ver y minor, ma y have significant impact on both conducted and radiated emi. more sp ecific guidance is given below w h en attempting to repeat this transformer design. 1. wire g aug e selectio n for core can c ellati on, se con dary and bias wi nding s ? ? ? ? ? ? ?
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 7.4 transformer build diagram wrapped copper foil 6 secondary #30 tiw 8t 7 4 shield & bias #31 26t 5 4 2 la y er tape 2 la y er tape 2.0 mm barrier t ape 4 layer each 1 st la y er: 14t 2.0 mm barrier tape 4 layers 2.25 mm barrier t ape 4 layers 2 1 3 sheild #32 33t 1 layer tape 4 layer tape 1 figure 6a ? tran sfo r mer build diag ra m. key: = electrical phasing = mechanical start; reversed winding di rection or same winding direction with bobbin rotated. page 13 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 35 mm +/- 0 .5 mm 41 mm +/- 0 .5 mm 14.9 mm 7.5 mm +/- 0.1 m m solder at center, same height as wire ma g net wire, item [3] tape item [9] 0.05 mm thick copper foil fold figure 6b ? foil con s truction diag ram. page 14 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 7.5 transformer construction bobbin prep aration pull pin 8-10 on bob bin [2] to provide pol arization. set bobbin wi th pins 1-5 on right hand si de. shield winding #1 start at pin 1. wind 33 turns of item [3 ] from right to left in 1 layer ac ross the entire wi d t h of the bobb in. basic insula tion tempo r a r ily termin ate wire on left hand side of bo bbi n. apply 1 layer of tape item [7]. terminate shield winding #1 termin ate item [3] on pin 3. cut pin 3 bel ow termi natio n to prevent contact with p c b trace. basic insula tion (con tinued ) apply an addi tional 3 layers of tape item [7]. primar y winding #2 start at pin 2. wind 100 tu rns of item [3] in 3 layers, p l us 3 to 5 add itional turns. wi nd uniformly a c ross the ent ire width of the bobbi n with n o empty spa c e o r gap s in any layer. finish at pin 1. foil shield asse mble a n d apply foil sh ield [4] startin g 3 mm from bottom side o f bobbi n [2]; such that foil termination wi re aligns with pi n 4. insert the foil shiel d assem b ly [4] beneath a 10-1 5 m m long pie c e of tape (to hol d in place). wrap ben eat h 1 layer item [7] and terminate foil at pin 4. margin tape apply 4 layers of item [11] on both si de s of the bobbin ensu r ing n o spa c e to either bob b i n wall. bobbin prep aration cha nge the b obbin [2] orie ntation with pi ns 6-10 on rig h t hand si de. maintain sam e spin dle rota tion dire ction. seconda r y winding #3 tempo r a r ily start at pin 1. wind 8 tu rns i t em [5] in 1 layer from left to right. wind u n iformly acro ss the e n tire width of the b obbin with no empty spa c e o r gap s in the layer. finish at pin 7. remove start from pin 1 an d reatta ch to pin 6. basic insula tion apply 2 layers tape item [7 ]. margin tape l and r apply 4 layers of item [11] on left side of the bobbin e n su ring n o sp ace to bobbi n wall. apply 4 layers of item [12] on ri ght si de of the bobbin ensurin g no space to bobbin wall . bias winding #4 start at pin 4. wind 14 turns item [6] from left to right. wind uniformly across the en tire width of the bob bin wit h no empty space or ga ps in the layer. basic insula tion apply 1 layer of tape item [6], maintainin g bias windin g exit at edge of margi n tape b a rri er. bias winding #4 (con tinued ) continue winding item [6] from right to left. wind a total of 26 turns item [6]. finish on pi n 5. oute r insulation apply 2 layers of tape item [7]. final assem bly as s e mble and s e c u re c o re halves with it em [12]. dip varni s h a nd cu re (do n o t vacuum im preg nate ) . page 15 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 7.6 transformer bobbin drawing page 16 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 8 performance dat a all measur ements performed at room temper ature, 60 hz input frequency. output voltage was measured at the en d of the d c output cable. input power was measured with a yok ogawa wt 120 power meter. 8.1 efficiency ef f i cien cy at f u ll l o ad - 0. 5a ( m easu r e d at en d o f cab le) 50 % 55 % 60 % 65 % 70 % 75 % 80 % 0 5 0 1 00 1 5 0 20 0 2 50 30 0 input v o lt a g e ( v a c ) efficiency (%) figure 7 - efficiency vs. input voltage, room te m peratu r e, 60 hz. ef f i c i en c y vs. o u t p u t c u rr en t ( m eas u r e d at en d o f ca b l e) 50 % 55 % 60 % 65 % 70 % 75 % 80 % 0 0 . 1 0. 2 0 . 3 0. 4 0 . 5 0. 6 lo a d c u rre n t ( a ) efficien cy (%) 85 v a c 115 v a c 190 v a c 230 v a c 265 v a c figure 8 - efficien cy vs. output load, room temp erature, 60 hz. page 17 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 8.2 no-load input power n o - l oa d p o w 0 0. 1 0. 2 0. 3 0. 4 0 5 0 100 150 200 250 300 in p u t v o lt a g e ( v a c ) input power (w) e r c ons u m pt i o n figure 9 - ze ro loa d input power vs. in put line volta ge, room t e mperature, 6 0 hz. page 18 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 8.3 8.3 regulation 8.3.1 line and load v/i c h a r act er is t i cs ( m easu r e d at en d o f cab le) 0 1 2 3 4 5 6 7 8 9 10 11 0 0 .1 0.2 0 .3 0.4 0 .5 0 . 6 0 .7 load c u rrent ( a ) output vol t age (vdc) 85 v a c 115 v a c 190 v a c 230 v a c 265 v a c figure 10 ? load reg u l a tion, room tempe r atu r e, 50 hz. page 19 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 8.4 thermal performance the thermal images prov ide detail of the power supply operating component temperatures. the images were recorded afte r operating the unit for 12 hours at 85 vac with an output load of 0.5 a at the maxim u m power point. this provides worst-case temperature rise on the linkswitch device. the top im age details component te mperatures of the assembly with the case removed. hotspots are visible at linkswitch and output diode locati ons, which reached 53 link switch a n d output diode c a s e temperatures of 68 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter output diod e , d7 link switc h link switc h output diod e , d 7 figure 1 1 ? t hermal imag e measur ements o f board an d se ale d ada p ter, 85 vac, 5.5 v at 0.5 a, 23 ? c ext e rna l ambi e n t. page 21 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 9 w aveforms 9.1 drain voltage and current, normal operation figure 12 - 8 5 vac, full load. upp e r: i drain , 0.1 a / div. lower: v drain , 100 v, 5 ? ?
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter figure 15 - s t art-up profile , 85 vac. 0.5 v, 100 ms / div. figure 16 - s t art-up profile , 265 vac. 0.5 v, 100 ms / div. 9.3 drain voltage and current start-up profile figure 17 - 8 5 vac input and maximu m load. upp e r: i drain , 0.1 a / div. lower: v drain , 100 v & 1 ms / div. figure 18 - 2 65 vac input and maximu m load. upp e r: i drain , 0.1 a / div. lower: v drain , 200 v & 1 ms / div. page 23 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 9.4 load tran sient response (75 % to 100 % load step) the oscilloscope was triggered using the lo ad current step as a trigger source. figure 19 ? tran sie n t re spo n se, 85
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 9.5 output ripple m easurements 9.5.1 ripple measurement technique for dc output ripple measurement s, a modified osc illoscope test probe must be utiliz ed in order to reduce spurious signals due to pi ckup. details of the probe modification are provided in figur e 21 and figure 22. the 5125ba probe ad apter is affixed with two capac itor s tied in parallel acros s the probe tip. the capacitors include one (1) 0.1 the aluminum electrolytic type c apac itor is polarized, so pr oper polarity across dc outputs m u st be m a intained (see below). probe ground probe tip figure 21 - o scill osco pe probe prepa re d for rippl e meas urement (end ca p an d grou nd le a d remove d). figure 22 - o scill osco pe probe with pro be maste r 51 25ba bnc a dapter (modifi ed with wi re s for probe grou nd for ri pple mea s u r e m ent, and two parallel de cou p ling cap a citors add e d ) . page 25 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 9.5.2 ripple measurement results all measur ements were made with ripple probe at the end of the dc tes t cable. a resistive lo ad was use d in all cas e s. figure 23 - ripple, 85 vac, full load. 2 ms, 50 mv / div. figure 24 - ripple, 230 va c, full load. 2 ms, 50 mv / div. page 26 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 10 conduct e d emi conducted emissions tests were completed at worst-case conditions: 230 vac at full load, 5.5 v/0.5 a. measurements with artificial hand connection are less than those with floating dc output load resistor. the output dc cable was included. the test sample exhibi ts greater than 10 db
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 figure 26 - condu cted em i, 230 vac, maximum dc load, output loa d floating. page 28 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 11 appendix a: ee16 simple , no foil, construction 11.1 introduction an alterna t ive desig n utiliz ing an ee1 6 trans former with simplified c o nstruction is presented. the transformer uses integral bi as and bifilar wound shields. these shields offer effecti v e emi attenuat ion with minimum additiona l transformer complexity. reduced c oupling bet ween bias and secondar y windings increases load regulation an d no-load out put voltage. a se condary snubber is required to reduce high frequency emi. efficiency is increased from 66% to 70%, due to a reduction in transformer primary-to- secondary leakage inductance. appen dix a presents schematic, bill of materials, transformer construction details a n d limited performance curves (including conducted emi). all specific ation requi rements are identic al to those presented in section 2. unles s specified, the performance of th is prototype is similar to t hose presented earlier; includin g output ripple, waveforms and thermal performance. 11.2 schematic the alternative ee16 transformer design is pi n compatible with the ep-54 printed circuit board. bias rectifier (d6b) and jumper (j1) are exchanged to maximize performance of the transformer bias shield. in addition, transfo rmer primary shield (pin 3) is tied to bulk dc return. component value changes are required to filter the increased leak age spike s een on the primary bias winding. this in cludes the clamp circuit (r1, c4) and primary bias circuitry (r3, r4). component additions include sec ondar y snubber circuit (r5, c7) and preload resistor (r 6). 11.3 bill o f m a terials highlighted item s are changes to previous design item qt y referen ce des c ription (t y p e) p/n, t y pe manufac ture r 1 1 u 1 linksw itch lnk5 2 0 p p o w e r integr ati o n s 2 2 c 1 , c 2 4.7 ?
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 11 1 d7 1 a, 60 v scho ttky 11dq0 6 internatio na l r e ctifier (or generic) 1 2 1 j 1 ju mp er, 24 a w g, b a r e (loc a t ion d6 b) g e n e r i c 13 1 l1 1.0 mh, 150 m a sbcp-47 hy10 2b t o kin 1 4 1 rf 1 8.2 ? ? ? ? ? ? ?
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 11.4 transformer specification 11.4.1 transformer winding 38 t #33 awg 1 2 4 5 7 6 primary 110 t #33 awg 12 t #26 tiw 11t #28x2 3 floating wd #1 wd #4 wd #3 second ary wd #2 figure 27 ? tran sfo r mer electri c al di a g ram, alternate ee16. 11.4.2 electrical specifications electrical st rength 60hz 1minute, from pins 1-5 to pins 6-7 3000 vac primary ind u ctance (pin 1 to pin 3) all windings open 2.73 mh +/- 10% resonant frequency all windings open 510 khz (min.) primary lea kage inductance pins 6-7 sho r ted 60 h (max. ) page 31 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 11.4.3 transformer build diagram 2 1 3 cut here 6 secondary side ta p e 7 5 4 primary side figure 28 ? tran sfo r mer build diag ra m, alternate ee16. 11.5 performance data all measur ements performed at room temperature, 60 hz input frequency. outp ut voltage was measured at the en d of the d c output cable. input power was measured with a yok ogawa wt 120 power meter. page 32 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter 11.5.1 efficiency e f f i c i en cy a t f u l l l o ad - 0 . 5 a ( m eas u r ed at en d o f ca b l e ) 50 % 55 % 60 % 65 % 70 % 75 % 80 % 0 5 0 1 0 0 15 0 2 0 0 25 0 3 0 0 i nput v o lta g e (v a c ) e ffi c i e n c y (% ) y figure 29 ? efficiency vs. input voltage , alternate ee 16, full loa d, room te m peratu r e, 60 hz. ef f i ci en cy ve r s u s o u t p u t c u r r e n t (me a s u re d a t e nd of c a bl e ) 50 % 55 % 60 % 65 % 70 % 75 % 80 % 0 0 .1 0 . 2 0 . 3 0.4 0 . 5 0.6 l o ad cu r r e n t (a) ef f i ciency ( % ) 8 5 vac 11 5 v a c 19 0 v a c 23 0 v a c 26 5 v a c figure 30 ? efficiency vs. output loa d, alternat e ee16, room t e mperature, 6 0 hz. page 33 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 11.5.2 line and load regulation v/i c h ar ac t e rist ic s, a l t e rn at e ee16 t r an sf o r mer ( m eas u r e d at en d o f c a b l e ) 0 1 2 3 4 5 6 7 8 9 10 11 0 0 . 1 0 . 20 . 3 0 . 40 . 5 0 . 60 . 7 l o a d cu r r en t (a ) output volta g e (vdc) 85 v a c 11 5 v a c 19 0 v a c 23 0 v a c 26 5 v a c figure 31 ? l i ne and l oad reg u lation, alternative ee16 tra n sfo r m e r de sig n . 11.6 conducted em i conducted emissions were measured at the peak output power poin t at worst-case nominal line voltage, 230 vac. measurements consider both ar tificial hand (connected to dc output load terminal) an d floating outputs. dc c able harness was included. the test sample exhibits greater than 10 db
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter figure 32 ? con d u c ted emi, alternative ee16 tran sfor mer desi g n , 230 vac, maximum dc l oad, with artific i al hand. figure 33 ? con d u c ted emi, alternative ee16 tran sformer, 2 30 vac, maximum dc lo ad, floating outp ut. page 35 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 12 revision history date author revision description & chang es 2 9 - s e p t - 2 0 0 3 s h 0 . 1 first d r a f t 01-oct-2003 pv 0.2 second dr aft (edits) 2 5 - f e b - 2 0 0 4 p v 1 . 0 third draft ( p h o t o ) 07-may-2004 sh 1.1 thermal image (labels) page 36 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter notes page 37 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 notes page 38 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
07-may-2004 EPR-54 ? linkswitch 2.75 w low cost charger / adapter notes page 39 of 40 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 www.po werint.co m
EPR-54 ? linkswitch 2.75 w low co st charger / adapter 07-may-2004 po w e r integrati ons tel: +1 408 414 9200 fa x: +1 4 08 414 9201 f o r th e l a t e st u p d at es, vi si t o u r w e b si te: www.p o w erint.co m pow e r inte g r a tions m a y m a ke c h a n g e s to its prod uc ts a t a n y ti m e . p o w e r inte g r a tions ha s no l i a b i lity a r ising f r o m y our use o f a n y inf o r m a tion, de v i c e or cir c ui t de s c r i be d he r e in nor d o e s it c o nv ey a n y lic e n s e unde r i t s pa te nt rig h ts or the r i g h ts of ot h ers . p o w e r int e g r at ions m akes no w a rr a n t i es herein a nd s p ecif ica l ly dis c l a im s all wa rr ant ies i n c l u d i n g , wi th o u t l i m i t a ti o n , th e i m p l i e d w a r r a n t i e s o f m e r c h an t a b i li ty , f i tn e s s f o r a p a rt icu l a r p u r p os e, a n d non-inf r ing e m e n t of t h ird p a rt y ri g h t s . patent inform ation t h e pr oduc ts a n d a p plic a tio n s ill us tr a t e d he r e in ( i nc lu di ng c i r c uits e x te r n a l to the pr od uc ts a nd tr a n s f or m e r c ons tr uc tion) m a y be c o v e r e d by one or m o r e u . s. a nd f o r e ig n pa te nts or po te ntia lly by p e nding u . s. a nd f o r e ig n pa te nt ap plic a tio ns a s s i g n e d to p o w e r i n te g r a tions . a c o m p le te lis t of pow e r i n te g r a tions ? pa te nts m a y be f ound a t www.p o werin t .c o m . th e p i lo go , topswitch, ti nyswitch , linkswitch , an d ecosmart ar e regi st er ed t r ad em arks o f p o w e r in t e grat i o n s . pi expert an d dpa-sw itc h a r e tr a d e m a r k s of p o w e r i n te g r a t ions . ? c o py r i g h t 200 4, pow e r i n te g r a tions . po w e r integr ations world w ide s a le s supp ort loc ations w o rl d he adquart e rs 5 245 hell yer a v en u e , sa n j o s e , c a 9 513 8, usa m a i n : + 1 - 4 08 -414 -92 0 0 c u st om er s e r v i c e: ph on e: + 1 - 4 08 -414 -96 6 5 f a x: +1- 4 0 8 - 4 1 4 - 9 76 5 e- m a i l : u s as al es @p ow er i n t . c o m ge rmany r u eck er t s t r a s s e 3 , d - 80 33 6, m u ni ch , g e r m any ph on e: + 4 9 - 895 -52 7 - 3 910 f a x: +4 9- 8 9 5 - 5 27- 39 2 0 e - m a i l : eu ro s a l e s@ p o w e ri n t .c o m j a p an kei h in -t a t em on o 1 s t b l d g . 12- 20 s h i n - y o k o h am a, 2- c h o m e , k o ho ku- ku , y o ko h a m a - s hi , k a n a ga w a 2 2 2 - 003 3, j a pa n ph on e: + 8 1 - 45 -471 -10 2 1 f a x: +8 1- 4 5 - 4 7 1 - 3 71 7 e- m a i l : ja pa ns al es @ p ow er i n t . c o m ta i w a n 5f - 1 , n o . 31 6, n e i h u r d ., s e c. 1 ne i hu di s t . t a ipe i , t a iw an 1 1 4 , r.o . c. p h o n e : +8 86- 2- 2 6 59- 45 7 0 f a x: +8 86- 2- 2 6 59- 45 5 0 e- m a i l : ta iw an s a les @ p o w er in t.c o m china (shanghai) r m 8 0 7 , p a ch eer , co m m e r c ial ce n t r e , 55 5 n a n j i n g w e s t ro ad , sh an gh ai , 200 041 , c h in a ph on e: + 8 6 - 21 -621 5 - 5 548 f a x: +8 6- 2 1 - 6 2 15- 24 6 8 e- m a i l : c h i n asa l es @ p o w er in t. com india (t ec hn i c al suppor t ) i n n ova t e c h 26 1/a , g r o und f l oo r 7t h ma in , 17 t h c r o ss, s a das h iv an ag ar b a n g a l ore 5 6 008 0 ph on e: + 9 1 - 80 -511 3 - 8 020 f a x: +9 1- 8 0 - 5 1 13- 80 2 3 e- m a i l : i n di asa l es @ p o w er i n t. com kore a 8t h f l o o r , d o ng s ung bl dg . 17- 8 y o i d o - do ng , you n g d e un gp o-gu , seou l, 1 5 0 - 874 , k o rea p h o n e : +8 2- 2- 78 2- 2 8 40 f a x: +8 2- 2- 78 2- 4 4 27 e- m a i l : kor e as al es @p ow er i n t . c o m uk (e urop e & a f rica he adquart e r s) 1 s t f l o o r, st . jame s?s ho u s e e a s t s t r eet f a r nham , su rre y g u 9 7t j u n ite d k i ng do m p h o n e : +4 4- 1 2 52- 73 0- 1 4 0 f a x: +4 4- 1 2 52- 72 7- 6 8 9 e - m a i l : eu ro s a l e s@ p o w e ri n t .c o m china (she nzhe n) r m # 170 5, b a o hua b l d g . 1 016 h u a q i an g b e i l u , s h en zh en , g u an gd o n g, 5 180 31 , ch in a p h o n e : +8 6- 7 5 5 - 8 36 7- 5 1 43 f a x: +8 6- 7 5 5 - 8 37 7- 9 6 10 e- m a i l : c h i n asa l es @ p o w er in t. com it al y v i a v i tto r io v e ne to 12 , b r e sso m i lan o , 2 009 1, i t a l y ph on e: + 3 9 - 028 -92 8 - 60 01 f a x: +3 9- 0 2 8 - 9 28- 6 0 0 9 e - m a i l : eu ro s a l e s@ p o w e ri n t .c o m singap ore 51 n e w t o n ro ad , #1 5- 0 8 / 1 0 g o l dhil l p l az a, si n g ap ore, 30 890 0 ph on e: + 6 5 - 635 8 - 2 160 f a x: +6 5- 6 3 58- 20 1 5 e- m a i l : s i nga po r e s a l e s @ po we r i nt . c o m ap p l icat ions hotl i ne w o rl d w i de +1- 4 0 8 - 4 1 4 - 9 6 60 a pplic a t ion s fa x w o rl d w i de +1- 4 0 8 - 4 1 4 - 9 7 60 page 40 of 40 www.po werint.co m

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