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Design Example Report
Title Specification Application Author Document Number Date Revision 2.4W Charger using TNY264P Input: 90 - 265 VAC Output: 6V / 0.4A Cell Phone Charger Power Integrations Applications Department
DER-4 February 4, 2004 1.0
Summary and Features
This report details the design of an isolated Flyback converter for a wall mount adapter. * * * * * * Uses TinySwitch TNY264P Universal input voltage Typical Efficiency 62 % at 400 mA load Meets EN550022 Class B EMI tests with No Y capacitor Very low earth leakage current Meets tight CC over temperature with no thermistor
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-4
2.4W Cell Phone Charger
February 4, 2004
Table Of Contents
1 2 3 4 5 6 Introduction................................................................................................................. 5 Power Supply Specification ........................................................................................ 5 Schematic................................................................................................................... 6 PCB Layout ................................................................................................................ 7 Bill Of Materials .......................................................................................................... 8 Transformer................................................................................................................ 9 6.1 Transformer Winding .............................................................................................. 9 6.2 Electrical Specifications .......................................................................................... 9 6.3 Materials ................................................................................................................. 9 6.4 Transformer Construction ..................................................................................... 10 6.5 Winding Instructions.............................................................................................. 11 6.6 Design Notes: ....................................................................................................... 11 7 Performance Data .................................................................................................... 12 7.1 Efficiency .............................................................................................................. 12 7.2 Regulation............................................................................................................. 13 7.3 No Load Input Power ............................................................................................ 13 7.4 Output Ripple Measurements ............................................................................... 14 7.4.1 Ripple Measurement Technique.................................................................... 14 7.4.2 Output Voltage Ripple.................................................................................... 15 8 EMI Tests ................................................................................................................. 16 9 Revision History ....................................................................................................... 18
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DER-4
2.4W Cell Phone Charger
February 4, 2004
List Of Figures
Figure 1 - Flyback Converter - 2.4W 6V 0.4A................................................................................................ 6 Figure 2 - PCB Layout .................................................................................................................................... 7 Figure 3 - Transformer Winding...................................................................................................................... 9 Figure 4 - Transformer construction ............................................................................................................. 10 Figure 5 - Efficiency Vs Output Current ........................................................................................................ 12 Figure 6 - Load Regulation ........................................................................................................................... 13 Figure 7 - No Load Input Power.................................................................................................................... 13 Figure 8 - Oscilloscope Probe Prepared for Ripple Measurement............................................................... 14 Figure 9 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter .................................................... 14 Figure 10 - Output Voltage Ripple (worst case) at Vin = 264 Vac, Vo = 6.0 V, Io = 400 mA ....................... 15 Figure 11 - EN55022 Class B, 110 Vac, Line (worst case), artificial hand connected to output return ....... 16 Figure 12 - EN55022 Class B, 220 Vac, Line (worst case), artificial hand connected to output return ....... 16 Figure 13 - EN55022 Class B, 110 Vac, Line (worst case), no artificial hand connected to output return .. 17 Figure 14 - EN55022 Class B, 220 Vac, Line (worst case), no artificial hand connected to output return .. 17
List Of Tables
Table 1 - Power Supply Specification ______________________________________________________ 5 Table 2 - Bill of Materials ________________________________________________________________ 8 Table 3 - Transformer BOM______________________________________________________________ 9
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-4
2.4W Cell Phone Charger
February 4, 2004
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DER-4
2.4W Cell Phone Charger
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 Output Ripple Voltage 1 Output Current Total Output Power Continuous Output Power POUT 2.4 W Symbol VIN VOUT1 VRIPPLE1 IOUT1 Min 90 5.7 375 6.0 Typ Max 265 6.3 150 425 Units Vac V mV mA
in constant voltage mode 20 MHz Bandwidth in constant current mode
Comment
Conducted EMI Margin Efficiency Ambient Temperature TAMB
5 50 -10 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-4
2.4W Cell Phone Charger
February 4, 2004
3 Schematic
C4 R7 1000pF,100V 5.1,1206 D1
1 6 5 W4,Secondarry, 12T,#25(TIW) + 8 2
T1 EE16 JP1
1 2
R2 200K,1/8W UG1B C5 470uF 10V Q1 MMBT3906
NC W1,Shield, 27T,#36x2 4
L2 Large Ferrite Bead
6 V, 0.4A
L1 1 mH C3 4700 pF,1KV
W2,Primary, 106T,#36 3
BR1 R3 240,1/8W
+
R4 330,5%,0805
L 4.7uF 400V C1 1N4007GP D5
+
R1
+1
DF06
NC W3,Shield, 10T,#35x5 4
L
2
3
10,1W
+
-
C6 100uF 10V R9 100,5%,0805 D7 BZX79C5.6V
90V-265 VAC
4.7uF 400V C2 D EN BP
4 1
N
N U2 C8 PC817D
3 2
4
(option) R10 L3 0.1uF 50V (option) U1 S TNY264P
R5 1,1%,0805 D6 1N4001 R6 1,1%,0805
R8 0, 5%,1206
RTN
Figure 1 - Flyback Converter - 2.4W 6V 0.4A.
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DER-4
2.4W Cell Phone Charger
February 4, 2004
4 PCB Layout
Figure 2 - PCB Layout
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DER-4
2.4W Cell Phone Charger
February 4, 2004
5 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 24 25 26 27 28 Qty 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Reference BR1 C1, C2 C3 C4 C5 C6 C8 D1 D5 D6 D7 JP1 L1 L2 L3 Q1 R1 R2 R3 R4 R5, R6 R7 R8 R9 R10 T1 U1 U2 Part DF06, 600 V, 1A, bridge rectifier 4.7F, 400V, AL electrolytic capacitor 4700 pF, 1KV, ceramic capacitor 1000 pF, 100V, 0805, ceramic capacitor 470 F, 10V, AL electrolytic low ESR capacitor 100 F, 10V, AL electrolytic low ESR capacitor 0.1 F, 50V, 0805, ceramic capacitor UG1B, 100V, 1A, 15 nSec, UFR 1N4007GP, 1000V, 1A, 2 S, glass passivated diode 1N4001, 50V, 1A, diode BZX79C5.6V, zener, 5.6V, 0.5W, 2% Jumper wire, # 22 AWG, 0.5 " 1 mH Inductor Large Ferrite Bead 1mH or Large ferrite bead (optional) MMBT3906, PNP transistor, 40V, 200 mA 10 , 1W, fusible resistor 200 K, 1/8W, 5% 240 , 1/8W, 5% 330 , 0805, 5%, 1.1 , 0805, 1%, 5.1 , 1206, 5% 0 , 1206, 5%, 100 , 0805, 1% 10 K, 1206, 5%, (optional) Flyback Transformer TNY264P PC817D, Optocoupler, CTR = 300 - 600 %
Table 2 - Bill of Materials
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DER-4
2.4W Cell Phone Charger
February 4, 2004
6 Transformer
6.1 Transformer Winding
NC W1,Core cancellation wndg, 27T,#36x2 4 5 W2,Primary, 106T,#36 3 NC W3,Shield Wndg, 10T,#35x5 4
Figure 3 - Transformer Winding
8 W4,Secondary, 12T,#25 TIW 6
6.2
Electrical Specifications
60Hz 1minute, from Pins 3-5 to Pins 6-8 All windings open All windings open L35 with pins 6-8 shorted 3 kV for 1 minute 1.78 mH - 2.05 mH 300 kHz min. 60 H max.
Electrical Strength Primary Inductance (Pin 3 to Pin 5) Resonant Frequency Primary Leakage Inductance
6.3
Materials Description Core: EE16, TDK Gapped for AL = 158.5 nH/T2 - 182.4 nH/T2 Bobbin: Horizontal 10 pins Magnet Wire: #35 AWG Magnet Wire: #36 AWG Triple Insulated wire: # 25 AWG Tape: 3M 1298 Polyester Film (white) 0.311" x 2 mils Varnish
Table 3 - Transformer BOM
Item [1] [2] [3] [4] [5] [6] [7]
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DER-4
2.4W Cell Phone Charger
February 4, 2004
6.4
Transformer Construction
Pins 6-10 Pins 1-5 0.311",2mils Insulation Tape, 1 layer 1 place, 2 layer 1 place, 3 layer 3 places, 4 layer 1 place W3-start(NC) W3-finish(P4) W2-finish(P5) W2-start(P3) W1-finish(NC) W1-start(P4)
W4-finish(P6) W4-start(P8)
Figure 4 - Transformer construction
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DER-4
2.4W Cell Phone Charger
February 4, 2004
6.5
Winding Instructions
Place the bobbin on the winding machine with pins 1-5 on the right side and pins 6-10 on the left side. W1 (Shield/ core cancellation winding) Basic Insulation W2 (Primary Winding) Wind 27 turns from right to left with # 36 x 2 (bifilar) AWG magnet wire starting from pin 4 and leave the finishing end open, bend the finishing end 90 and cut the wire in the middle of the bobbin width. 4 layers of tape for insulation. Wind 106 turns in 2 layers with # 36 AWG magnet wire - first layer 53T from right to left starting from pin 3 - one layer of insulation tape - second layer 53T from left to right and finishing at pin 5. 3 layers of tape for insulation. Wind 10 turns with #35 x 5 (penta-filar) magnet wire from left to right starting temporarily from pin 8, and finishing at pin 4. Extend the start end to cover any gap, then bend 90 and cut the wire in the middle of the bobbin width. 2 layers of tape for insulation. Wind 12 turns with # 25 triple insulated wire from left to right starting from 8 and finishing at 6. 3 layers of tape for insulation. Assemble and secure core halves. Impregnate transformer uniformly with varnish.
Basic Insulation W3 (Shield winding)
Basic Insulation W4 (Secondary Winding) Outer Insulation Core Assembly Final Assembly 6.6
Design Notes: TNY264P 132 KHz Continuous/ discontinuous 0.25 A 71.5 V 264 V 90 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-4
2.4W Cell Phone Charger
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
70.00 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-4 7.2 Regulation
2.4W Cell Phone Charger
February 4, 2004
Load Regulation
7 6 Output Voltage (V) 5 4 Vin = 90 Vac 3 2 1 0 0 100 200 300 400 500 Output Current (m A) Vin = 120 Vac Vin = 220 Vac Vin = 264 Vac Upper limit Low er Limit
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-4 7.4
2.4W Cell Phone Charger
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-4
2.4W Cell Phone Charger
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
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DER-4
2.4W Cell Phone Charger
February 4, 2004
8 EMI Tests
The EMI tests are done at 110 Vac and 220 Vac inputs, Line (worst case) and 15 (395 mA approx.) load. To obtain more margin in radiated EMI, use L3 = Long ferrite bead. With L3 = 1 mH and R10 = 5.1 K, radiated EMI will improve even more, and conducted EMI will also improve.
Figure 11 - EN55022 Class B, 110 Vac, Line (worst case), artificial hand connected to output return
Figure 12 - EN55022 Class B, 220 Vac, Line (worst case), artificial hand connected to output return
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DER-4
2.4W Cell Phone Charger
February 4, 2004
Figure 13 - EN55022 Class B, 110 Vac, Line (worst case), no artificial hand connected to output return
Figure 14 - EN55022 Class B, 220 Vac, Line (worst case), no artificial hand connected to output return
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DER-4
2.4W Cell Phone Charger
February 4, 2004
9 Revision History
Date February 4, 2004 Author MJ Revision 1.0 Description & changes First Release Reviewed AM/VC
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DER-4
2.4W Cell Phone Charger Notes
February 4, 2004
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DER-4
2.4W Cell Phone Charger
February 4, 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. 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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