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Design Example Report
Title Specification Application Author Document Number Date Revision 2.4W Charger using TNY264P Input: 85 - 265 VAC Output: 6V / 0.4A Cell Phone Charger Power Integrations Applications Department DER-3 February 4, 2004 1.0
Summary and Features
This report details the design of an isolated Flyback converter for Wall mount adapter. * * * * * Uses TinySwitch TNY264 Universal input voltage Typical Efficiency 62 % Meets EN550022 Class B EMI tests with No Y1 capacitor Very low earth leakage current
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. Applications Hotline: Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com
DER-3
2.4W Battery Charger/Adapter
February 4, 2004
Table Of Contents
Introduction................................................................................................................. 4 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 PCB Layout ................................................................................................................ 6 Bill Of Materials .......................................................................................................... 7 Transformer................................................................................................................ 8 6.1 Transformer Winding .............................................................................................. 8 6.2 Electrical Specifications .......................................................................................... 8 6.3 Transformer Construction ....................................................................................... 9 6.4 Winding Instructions................................................................................................ 9 6.5 Materials ............................................................................................................... 10 6.6 Design Notes: ....................................................................................................... 10 7 Performance Data .................................................................................................... 11 7.1 Efficiency .............................................................................................................. 11 7.2 Regulation............................................................................................................. 12 7.3 No Load Input Power ............................................................................................ 12 7.4 Output Ripple Measurements ............................................................................... 13 7.4.1 Ripple Measurement Technique.................................................................... 13 7.4.2 Output Voltage Ripple.................................................................................... 14 8 EMI Tests ................................................................................................................. 15 9 Revision History ....................................................................................................... 17 1 2 3 4 5 6
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
List Of Figures
Figure 1 - Flyback Converter - 2.4W 6V 0.4A................................................................................................ 5 Figure 2 - PCB Layout .................................................................................................................................... 6 Figure 3 - Transformer Winding...................................................................................................................... 8 Figure 4 - Transformer construction ............................................................................................................... 9 Figure 5 - Efficiency Vs Output Current ........................................................................................................ 11 Figure 6 - Load Regulation ........................................................................................................................... 12 Figure 7 - No Load Input Power.................................................................................................................... 12 Figure 8 - Oscilloscope Probe Prepared for Ripple Measurement............................................................... 13 Figure 9 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter .................................................... 13 Figure 10 - Output Voltage Ripple (worst case) at Vin = 264 Vac, Vo = 6.0 V, Io = 400 mA ....................... 14 Figure 11 - EN55022 Class B, Line, artificial hand connected to output return ........................................... 15 Figure 12 - EN55022 Class B, Neutral, artificial hand connected to output return....................................... 15 Figure 13 - EN55022 Class B, Line, with out artificial hand connected to output return .............................. 16 Figure 14 - EN55022 Class B, Neutral, with out artificial hand connected to output return ......................... 16
List Of Tables
Table 1 - Power Supply Specification ______________________________________________________ 4 Table 2 - Bill of Materials ________________________________________________________________ 7 Table 3 - Transformer BOM_____________________________________________________________ 10
Important Notes: 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.
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
1 Introduction
This document is an engineering report giving performance characteristics of an isolated Flyback converter with universal input voltage and 6V 0.4A output CV/ CC characteristics. This design uses TinySwitch - an integrated IC comprising a high voltage MOSFET, PWM controller. This document contains the power supply specification, schematic, and bill of materials, transformer documentation, printed circuit layout, and performance data.
2 Power Supply Specification
Description Input Voltage Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Constant Current Limit Conducted EMI Margin Efficiency Ambient Temperature TAMB -10 POUT 0.4 2.4 W A Symbol VIN VOUT1 VRIPPLE1 IOUT1 Min 85 5.7 6.0 Typ Max 264 6.3 100 0.4 Units Vac V mV A
at 400 mA load 20 MHz Bandwidth
Comment
5 50 40
dB
o
EN550022 B, FCC B At full load Free convection, Sea level
% C
Table 1 - Power Supply Specification
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
3 Schematic
T1 EE13 R1 51 D1
7 4 W2,Primary, 99T,#36 + 8 3 1 W3,Shield, 6T,#33X5 2 W4,Secondarry, 10T,#25(TIW)
470pF,100V C1
R2 C3 2200 pF 1KV 200K 11DQ06 C2 220uF 10V
NC W1,Shield, 25T,#36X2 2
L1 Large Ferrite Bead
6 V, 0.4A
10K 1/8W D3 1N4005 R5 200,1/8W Q1 2N3906
+
100pF 1KV
R4
C4
R3 330 1/8W
D2
L2
1N4005
in
1 mH C6 4.7uF 400V D EN BP
4 1
+
90V-265 VAC
U2 LTV817A U1 TNY264 D7 C8
3 2
D4 1N4937
D5 BZX79C5.6V R6 100 1/8W
C5 100uF 10V
L3
in
1mH S 0.1uF 50V
D6 1N4005
R7
C7
1N4005
R8 1.5 1/8W 5% D8 1N4001 R9 1.5 1/8W 5% RTN
10K 1/8W
100 pF 1KV
Figure 1 - Flyback Converter - 2.4W 6V 0.4A.
Page 5 of 19
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
4 PCB Layout
Figure 2 - PCB Layout
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
5 Bill Of Materials
Item Quantity Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 C1 C2 C3 C4 C5 C6 C7 C8 D1 D2, D3, D6, D7 D4 D5 D8 L1 L2 L3 Q1 R1 R2 R3 R4, R7 R5 R6 R8 R9 T1 U1 U2 Part 470 pF, 100V, Ceramic capacitor 220 F, 10V, Low ESR AL capacitor 2200 pF, 1KV, Ceramic capacitor 100 pF, 1KV, Ceramic capacitor 100 F, 10V, Low ESR AL capacitor 4.7 F, 400V, AL capacitor 100 pF, 1KV, Ceramic capacitor 0.1 F, 50V, Ceramic capacitor 11DQ06, 60V, 1.1A Schottky diode 1N4005, 600V, 1A GP diode 1N4937, 600V, 1A, FR diode BZX79C5.6V, 5.6V Zener diode 1N4001, 100V, 1A, GP Diode Large Ferrite Bead 1 mH, Inductor 1mH, Inductor 2N3906, PNP Transistor 51 , 1/4W, 5% 200 K, 1/4W, 5% 330 , 1/8W, 5% 10 K, 1/8W, 5% 200 , 1/8W, 5% 100 , 1/8W, 5% 1.5 , 1/8W, 5% 1.5 , 1/8W, 5% Flyback Transformer TNY264, TinySwitch LTV817A, Optocoupler
Table 2 - Bill of Materials
Page 7 of 19
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
6 Transformer
6.1 Transformer Winding
NC W1,Shield Wndg, 25T,#36x2 2 4 W2,Primary, 99T,#36 3 1 W3,Shield Wndg, 6T,#36x5 2
Figure 3 - Transformer Winding
7 W4,Secondary, 10T,#25 TIW 8
6.2
Electrical Specifications
60Hz 1minute, from Pins 1-4 to Pins 7-8 All windings open All windings open L34 with pins 5-6 shorted 3 kV for 1 minute 1.31 mH - 1.6 mH 300 kHz min. 40 H max.
Electrical Strength Primary Inductance (Pin 3 to Pin 4) Resonant Frequency Primary Leakage Inductance
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
6.3
Transformer Construction
Pins 1-4 Pins 5-8 0.29",2mils Insulation Tape, 1 layer 1 place, 2 layer 2 places, 3 layer 1 place, 4 layer 1 place W3-finish(P1) W3-start(P2) W2-finish(P4) W2-start(P3) W1-finish(NC) W1-start(P2)
W4-start(P7) W4-finish(P8)
Figure 4 - Transformer construction
6.4
Winding Instructions
Place the bobbin on the winding machine with pins 1-4 on the right side and pins 5-8 on the left side. W1 (Shield) Wind 25 turns from right to left with # 36 x 2 (bifilar) AWG magnet wire starting from pin 2 and leave the finishing end open. 4 layers of tape for insulation. Wind 99 turns in 2 layers with # 36 AWG magnet wire - first layer 50T from right to left starting from pin 3 - one layer of insulation tape - second layer 49T from left to right and finishing at pin 4. 2 layers of tape for insulation. Wind 6 turns with #36 x 5 (penta-filar) magnet wire from right to left starting from 2 and finishing at 1. 2 layers of tape for insulation. Wind 10 turns with # 25 triple insulated wire from right to left starting temporarily from 1 and finishing at 8. Bring the starting end from pin 1 to pin 7. 3 layers of tape for insulation. Assemble and secure core halves. Impregnate transformer uniformly with varnish.
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Basic Insulation W2 (Primary Winding)
Basic Insulation W3 (Shield) Basic Insulation W4 (Secondary Winding) Outer Insulation Core Assembly Final Assembly
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DER-3 6.5 Materials Item [1] [2] [3] [4] [5] [6]
2.4W Battery Charger/Adapter
February 4, 2004
Description Core: EE13, PC40EE13, TDK Gapped for AL = 148 nH/T2 Bobbin: Horizontal 8 pins Magnet Wire: #36 AWG Triple Insulated wire: # 25 AWG Tape: 3M 1298 Polyester Film (white) 0.29" x 2 mils Varnish
Table 3 - Transformer BOM
6.6
Design Notes: TNY264 132 KHz Continuous/ discontinuous 0.25 A 75 V 264 V 85 V
Power Integrations Device Frequency of Operation Mode Peak Current Reflected Voltage (Secondary to Primary) Maximum AC Input Voltage Minimum AC Input Voltage
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
7 Performance Data
All measurements are performed at room temperature unless otherwise specified. The output voltages are measured at the end of a 6-foot cable with 0.2 total resistance. 7.1 Efficiency
The measurements are made for various load and line conditions. The efficiencies are calculated and shown in Figure 5.
Efficiency Vs Output Current
65.00 60.00 Efficiency (%) 55.00 50.00 45.00 40.00 35.00 30.00 50 100 150 200 250 300 350 400 Output Current (mA) Vin = 90 Vac Vin = 120 Vac Vin = 220 Vac Vin = 264 Vac
Figure 5 - Efficiency Vs Output Current
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DER-3 7.2 Regulation
2.4W Battery Charger/Adapter
February 4, 2004
Load Regulation
7 6 Output Voltage (V) 5 4 3 2 1 0 0 100 200 300 400 500 Output Current (m A) Vin = 90 Vac Vin = 120 Vac Vin = 220 Vac Vin = 264 Vac
Figure 6 - Load Regulation
7.3
No Load Input Power
No Load Input Power
300
Input Power (mW)
250
200
150 Io = 0 mA 100 50 100 150 200 250 300 Input Voltage (Vac)
Figure 7 - No Load Input Power
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DER-3 7.4
2.4W Battery Charger/Adapter
February 4, 2004
Output Ripple Measurements
7.4.1 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 8 and Figure 9. 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 8 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 9 - 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-3
2.4W Battery Charger/Adapter
February 4, 2004
7.4.2 Output Voltage Ripple
Figure 10 - Output Voltage Ripple (worst case) at Vin = 264 Vac, Vo = 6.0 V, Io = 400 mA
Page 14 of 19
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
8 EMI Tests
The EMI tests are done at 220 Vac input and 15 (400 mA) load.
QP
Avg
Figure 11 - EN55022 Class B, Line, artificial hand connected to output return
QP
Avg
Figure 12 - EN55022 Class B, Neutral, artificial hand connected to output return
Page 15 of 19
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
QP
Avg
Figure 13 - EN55022 Class B, Line, with out artificial hand connected to output return
QP
Avg
Figure 14 - EN55022 Class B, Neutral, with out artificial hand connected to output return
Page 16 of 19
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
9 Revision History
Date February 4, 2004 Author MJ Revision 1.0 Description & changes Initial release Reviewed AM/VC
Page 17 of 19
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DER-3
2.4W Battery Charger/Adapter Notes
February 4, 2004
Page 18 of 19
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DER-3
2.4W Battery Charger/Adapter
February 4, 2004
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, nor does it convey any license under its patent rights or the rights of others. 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, Inc. PI Expert and DPA-Switch are trademarks of Power Integrations, Inc. (c) Copyright 2003, Power Integrations, Inc.
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