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| Title Reference Design Report for 1.6 W, Linear Replacement Adapter with 10 kV surge withstand Specification 85-265 VAC Input, 7.7 V, 210 mA Output Application Author Document Number Date Revision Cordless Phone Adapter Power Integrations Applications Department RDR-83 Sept 29, 2006 1.0 Summary and Features * Highly efficient, low cost switching solution * Replacement for existing AC line transformer based design * Designed to withstand 10 kV common-mode surges * Ideal for applications connected to telephone network * EcoSmart(R) - meets all existing and proposed harmonized energy efficiency standards including: CECP (China), CEC, EPA, AGO, European Commission * No-load power consumption <220 mW at 265 VAC * 61.3% active-mode efficiency (exceeds requirement of 53.2%) * Integrated LinkSwitch safety/reliability features: * Accurate ( 5%), auto-recovering, hysteretic thermal shutdown function maintains safe PCB temperatures under all conditions * Auto-restart protects against output short circuits and open feedback loops * Meets EN55022 and CISPR-22 Class B conducted EMI with >15 dBV margin * Meets IEC61000-4-5 Class 4 AC line surge 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. RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 Table Of Contents Introduction.................................................................................................................3 Power Supply Specification ........................................................................................4 2.1 Typical Output Characteristic and limits ..............................................................5 3 Schematic...................................................................................................................6 4 Circuit Description ......................................................................................................7 4.1 Input Stage ..........................................................................................................7 4.2 LinkSwitch-LP......................................................................................................7 4.3 Feedback.............................................................................................................8 4.4 Output Rectification .............................................................................................9 5 PCB Layout ..............................................................................................................10 6 Bill Of Materials ........................................................................................................11 7 Transformer Specification.........................................................................................12 7.1 Electrical Diagram .............................................................................................12 7.2 Electrical Specifications.....................................................................................12 7.3 Materials............................................................................................................12 7.4 Transformer Build Diagram ...............................................................................13 7.5 Transformer Construction..................................................................................13 8 Design Spreadsheets ...............................................................................................14 9 Performance Data ....................................................................................................19 9.1 Efficiency ...........................................................................................................19 9.1.1 Active Mode ENERGY STAR / CEC Efficiency Measurement Data...........20 9.2 No-load Input Power..........................................................................................21 9.3 Available Standby Output Power.......................................................................21 9.4 Regulation .........................................................................................................22 9.4.1 VI Curve vs. Input Voltage..........................................................................22 10 Thermal Performance ...........................................................................................23 10.1 LNK562 Temperature Rise................................................................................23 10.2 Thermal Image ..................................................................................................23 11 Waveforms............................................................................................................24 11.1 Drain Voltage and Current, Normal Operation...................................................24 11.2 Output Voltage Start-up Profile..........................................................................24 11.3 Drain Voltage and Current Start-up Profile ........................................................25 11.4 Load Transient Response (50% to 100% Load Step) .......................................26 11.5 Output Ripple Measurements............................................................................27 11.5.1 Ripple Measurement Technique ................................................................27 11.5.2 Measurement Results ................................................................................28 12 Line Surge.............................................................................................................29 13 Conducted EMI .....................................................................................................30 14 Revision History ....................................................................................................32 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. 1 2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 1 Introduction This reference design report describes a switched-mode power supply that was designed to replace line frequency transformer based solutions. The supply uses a member of the LinkSwitch-LP family of devices, and is capable of withstanding common-mode line surges of up to 10 kV. That is often a requirement for applications that connect to a telephone line, such as modems, cordless phones and answering machines. The report includes the power supply specification, a circuit diagram, a bill of materials, transformer documentation, a printed circuit layout board, and performance data. Figure 1 - Populated Circuit Board Photograph. Page 3 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 2 Power Supply Specification Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power No Load Output Voltage Efficiency Full Load Required average efficiency at 25, 50, 75 and 100 % of POUT Environmental Conducted EMI Safety Surge Differential Mode Common Mode Surge Ambient Temperature TAMB Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Symbol VIN fLINE Min 85 47 Typ Max 265 64 0.3 8.7 400 Units VAC Hz W V mV A W V % % Comment 2 Wire - no P.E. 50/60 VOUT1 VRIPPLE1 IOUT1 POUT 6.7 0.21 1.4 7.7 0.21 1.6 20 MHz bandwidth 11 CEC 60 53 Measured at POUT 25 C Per ENERGY STAR / CEC requirements o 2 6 2 0 10 50 kV kV KV o 1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: 12 100 kHz ring wave, 500 A short circuit current, differential Free convection, sea level C Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 2.1 Typical Output Characteristic and Limits The following diagram shows the output characteristic of the LinkSwitch-LP solution and that of the linear transformer solution it was designed to replace. As can be seen, the LinkSwitch-LP solution provides a more controlled output characteristic. 18 115 VAC 16 14 12 UPPER LIMIT LOWER LIMIT Linear Adapter RD-83 115 VAC Volts 10 8 6 4 2 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Amps Figure 2 - Output Characteristic Comparison and Limits. Page 5 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 3 Schematic Figure 3 - Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 4 Circuit Description 4.1 Input Stage Components C1, C6, L1 and L3 comprise a balanced filter. Resistor R5 dampens low frequency conducted EMI. The supply needs no Y1-type capacitor (that normally bridges the primary to secondary isolation barrier) due to U1's frequency jitter function and the E-ShieldTM techniques used in the design of transformer T1. This minimizes audible noise in applications connected to a phone line, by eliminating a path for line frequency leakage currents to pass onto the output of the supply. The supply easily meets EN55022B conducted EMI limits, with more than 15 dBV of margin. A metal oxide varistor (RV1) and a wire wound resistor (RF1) attenuate differential line surges. The varistor is required to meet the 2 kV differential surge requirement. In applications where only 1 kV of surge immunity is required, RV1 can be eliminated. The wire wound resistor (RF1) must be able to withstand high transient dissipation from initial inrush current (when AC power is applied) and during line surges. 4.2 LinkSwitch-LP The LinkSwitch-LP family of ICs were designed to replace linear transformer solutions in low-power charger and adapter applications. Feedback to the LNK562P IC (U1) is derived from a resistor divider (R1 and R2) across the bias supply (D3 and C3), which lowers cost by eliminating the need for an optocoupler. Linear transformers typically use thermal fuses (over temperature cut-outs) for overload protection. However, once a thermal fuse trips, the entire charger or adapter must be thrown away, since thermal fuses cannot be reset or repaired. Latching thermal shutdown functions are typically used in ringing choke converter (RCC) based supplies. However, AC input power must be removed and reapplied to reset most thermal latches. Since customers typically don't know this, they often return good units they thought were defective, simply because the thermal latch tripped and shut the unit off. The LinkSwitchLP family's hysteretic thermal shutdown function has a very tight tolerance (142 C, 5%), and automatically restarts the power supply once the IC temperature drops below the lower temperature threshold. This maintains the average PCB temperature at a safe level under all conditions, and reduces the return rate of good units from the field. The auto-recovery feature also eliminates the noise sensitivity and component aging problems associated with discrete latching circuits. Pin 6 is eliminated from the IC package to extend the creepage distance between the DRAIN pin and all other low voltage pins; both at the package and on the PCB. This reduces the likelihood that tracking or arcing will occur due to moisture or board surface contamination (from dust and dirt), which improves reliability in high humidity and high pollution environments. During an output short circuit or an open loop condition, the LinkSwitch-LP's auto-restart function limits output power to about 12% of the maximum. This protects both the load and the supply during prolonged overload conditions. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 7 of 36 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 The LinkSwitch-LP family of ICs are self-biased, via a high-voltage current source that is internally connected to the DRAIN pin of the package. A capacitor (C2) connected to the BYPASS (BP) pin of the IC provides energy storage and local decoupling of the internal chip power. To further reduce no-load power consumption, a resistor can be used to provide operating current to the IC from the bias winding (once the power supply is operating). In this design, the bias winding voltage is about 14 V and the BP pin voltage is 5.8 V. Therefore, R6 (100 k) provides about 80 A of current to the BP pin. If the value of R6 were reduced, it could provide the entire 220 A of IC supply current, which would further reduce the no-load power consumption of the supply. The worst-case, no-load power consumption of this supply is approximately 200 mW at an input voltage of 265 VAC, which is well below the maximum limit of most energy efficiency standards. Heat generation is also kept to a minimum in this design, given the high operating efficiency at all line and load conditions. 4.3 Feedback The output voltage of the supply is regulated based on feedback from the primary-side bias supply. The bias winding voltage is rectified and filtered by D3 and C3. The leakage inductance between the output winding and the bias winding induces error in the bias winding voltage. Using a standard rectifier diode for D3 makes the bias winding voltage more accurately track the output voltage. Resistor R7 preloads (3 mA) the output of the bias supply, which further reduces the error and also limits the no-load output voltage. A resistor divider (R1 and R2) provides the feedback voltage to the FB pin of U1. The values of R1 and R2 are selected so that when the output voltage is at the desired nominal value, the voltage on the FB pin is 1.69 V, and about 70 A flows into the FB pin. The LinkSwitch-LP family of devices use ON/OFF control to regulate the output of the supply. During constant voltage (CV) operation, switching cycles are skipped when the current into the FB pin exceeds 70 A. As the load on the output of the supply reduces, more switching cycles are skipped. As the load increases, fewer cycles are skipped. The result is that the average or effective switching frequency varies with the load. This makes the efficiency fairly consistent over the entire load range, since the switching losses scale with the load on the output of the supply. When the load on the output of the supply reaches its maximum power capability, no switching cycles are skipped. If the load is increased beyond that point, the output voltage of the supply will start to drop. As the output voltage drops, the voltage on the FB pin also drops, and the IC linearly reduces its switching frequency. This keeps the output current from increasing significantly. Once the FB pin voltage falls below 0.8 V for more than 100 ms, all LinkSwitch-LP devices enter an auto-restart mode. While in auto-restart, the controller enables MOSFET switching for 100 ms. If the FB pin voltage does not exceed 0.8 V during the 100 ms, the controller disables MOSFET switching. MOSFET switching is alternately enabled and disables at a duty cycle of about 12% until the fault condition clears. This protects both the supply and the load. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 4.4 Output Rectification The transformer secondary winding is rectified by D4 and filtered by C4. A small preload resistor (R8) limits the no-load output voltage. Decreasing the value of the preload resistor will further reduce the no-load output voltage, at the expense of increasing the no-load input power consumption. In this design, a fast diode (rather than an ultra-fast) was used for D4 to lower cost and EMI emissions. Page 9 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 5 PCB Layout During a common mode surge, the specified surge voltage appears across the isolation barrier. Elimination of the optocoupler and Y1-type capacitor in the design allowed the necessary PCB clearance and creepage distance to be obtained, so that the supply can withstand a 10 kV surge without resorting to expensive, special components. To increase the creepage and clearance, the standard triple insulated wire used for the secondary winding was terminated as flying leads that were soldered directly into the PCB, instead of being terminated to transformer bobbin pins. A 0.185 inch long, 4.7 mm wide slot was placed along the isolation barrier. Additionally, the primary and secondary traces are separated by 0.4 inches (10 mm). A spark gap was added across the isolation barrier (marked as points (B) in Figure 4), so that any arcing that might occur would take place at a designated point with a well defined path. On the primary side of the isolation barrier, the spark gap trace returns directly to C6, which keeps surge currents away from the low-voltage pins of U1. Two additional spark gaps were placed across L1 and L3, to prevent the breakdown of insulation on those parts. Note: During 10 kV common mode surge testing, no arcing occurred across any of the spark gaps. (A) (B) (B) Figure 4 - RD83 Printed Circuit Layout (2.175" x 1.475" / 55.25 mm x 37.47 mm). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 6 Bill Of Materials Item Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 Ref Description Des 2 C1, C6 3.3 F, 400 V, Electrolytic, (8 x 11.5) 1 C2 1 C3 1 C4 1 D1 100 nF, 50 V, Ceramic, Z5U 10 F, 50 V, Electrolytic, Gen. Purpose, (5 x 11) Manufacturer Nippon Chemi-Con Panasonic Nippon Chemi-Con Manufacturer Part # ESMQ401ELL3R3MHB5D ECU-S1H104MEA EKMG500ELL100ME11D ELXZ250ELL101MFB5D 1N4937 1N4005 1N4933 5012 Nippon Chemi-Con 100 F, 25 V, Electrolytic, Low ESR, 250 m, (6.3 x 11.5) 600 V, 1 A, Fast Recovery Diode, 200 ns, DO-41 Vishay Vishay Vishay Keystone Generic N/A Tokin Yageo Yageo Yageo Yageo Vitrohm Littlefuse Hical Magnetics CWS Santronics 2 D2, D3 600 V, 1 A, Rectifier, DO-41 1 D4 2 J1, J2 1 J3 2 J4, J5 50 V, 1 A, Fast Recovery, 200 ns, DO-41 Test Point, WHT, THRU-HOLE MOUNT Output cord, 6 ft, 22 AWG, 0.25 , 2.1 mm connector PCB Terminal Hole, 22 AWG N/A SBCP-47HY102B MFR-25FBF-22K1 MFR-25FBF-3K01 CFR-25JB-4K7 CFR-25JB-100K CRF253-4 10R V275LA4 SIL6043 EP-83 SNX1388 2 L1, L3 1 mH, 0.15 A, Ferrite Core 1 R1 1 R2 22.1 k, 1%, 1/4 W, Metal Film 3.01 k, 1%, 1/4 W, Metal Film 3 R5, R7, 4.7 k, 5%, 1/4 W, Carbon Film R8 1 R6 100 k, 5%, 1/4 W, Carbon Film 1 RF1 1 RV1 T1 10 , 2.5 W, Fusible/Flame Proof Wire Wound 275 V, 23 J, 7 mm, RADIAL Custom Transformer Core: EE16, See Power Integration's document EPR-83 for Transformer Specification Bobbin: Horizontal Extended Creepage 5+5 pin Taiwan Shulin TF-1613 www.bobbin.com.tw Power Integrations LNK562P 19 1 U1 LinkSwitch-LP, LNK562P, DIP-8B Note: For reduced line frequency ripple at 85 VAC, increase the values of C1 and C6 to 4.7 F. Page 11 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 7 Transformer Specification 7.1 Electrical Diagram WD #1 3 Bias/Core Cancellation 29T #37AWG X 2 1 LAYER 4 2 Primary 176T #37AWG 3 LAYERS 1 FL WD #4 Secondary 17T #30AWG TIW FL NC Shield WD #3 15T #32 AWG X 2 1 WD #2 Figure 5 -Transformer Electrical Diagram. 7.2 Electrical Specifications 1 second, 60 Hz, from Pins 1-4 to Flying leads Pins 1-2, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with flying leads shorted, measured at 100 kHz, 0.4 VRMS 6000 VAC 3.5 mH, 10% 250 kHz (Min.) 115 H (Max.) Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: PC40EE16-Z, TDK or equivalent gapped for AL of 114 nH/T2. Gap approx. 0.2 mm. Bobbin: EE16 Horizontal 10 pin Taiwan Shulin TF-1613 or equivalent Magnet Wire: #37 AWG Magnet Wire: #32 AWG Triple Insulated Wire: #30 AWG Tape, 3M 1298 Polyester Film, 2.0 Mils thick, 8 mm wide Varnish Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 7.4 Transformer Build Diagram WD #4 Secondary Pin 1 Pin 1 Tape FLYING LEAD FLYING LEAD (MARKED) Tape Tape NC WD #3 Shield WD #2 Primary Pin 2 Pin 3 Pin 4 Tape WD #1 Cancellation Figure 6 - Transformer Build Diagram. 7.5 Transformer Construction Bobbin orientation is such that primary pins are on the left hand side of the winding spindle WD1 Cancellation and Bias Winding Insulation WD #2 Primary Winding Insulation WD #3 Shield Winding Insulation WD #4 Secondary Winding Outer insulation Gap Core Core Assembly and trim flying leads Varnish Primary pin side of the bobbin oriented to the left hand side. Temporarily start at pin 7. Wind 29 bifilar turns of item [3] from right to left. Wind with tight tension evenly across the bobbin. Terminate finish on pin 4. Take the end of the winding that was started on pin 7 and terminate it on pin 3. 1 Layer of tape [6] for insulation. Start at Pin 2. Wind 58 turns of item [3] from left to right. Then wind 59 turns on the next layer from right to left. Wind 59 turns from left to right on the third layer. Wind with tight tension evenly across the bobbin. Bring the wire across the bobbin and terminate the finish on pin 1. Use one layer of tape [6] for basic insulation. Temporarily start at Pin 7. Wind 15 bifilar turns of item [4]. Wind from right to left with tight tension across the entire bobbin width. Terminate on pin 1. Cut the wire from Pin 7 and leave it unconnected. Use three layers of tape [6] for basic insulation. Temporarily start at Pin 7 (allow 1" of wire at the start for the flying lead). Wind 17 turns of item [5] from right to left with tight tension. Allow 1" of wire at the finish for the flying lead, at the right side of bobbin. Remove the start from pin 7 and mark. Exit start at right hand side of the bobbin. Wrap windings with three layers of tape [6]. Gap core such that the inductance between pins 1 & 2 is 3.5 mH 10%. The gap is approximately 0.2 mm. Assemble and secure the core halves. Trim flying leads to 0.65"0.05". Tin leads 0.15"0.05". Cut bobbin pins 5,6,7 and 8. Dip varnish assembly with item [7]. Page 13 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 8 Design Spreadsheets ACDC_LinkSwitchLP_053106; Rev.1.12; Copyright Power Integrations 2006 VACMIN VACMAX fL VO IO Constant Voltage / Constant Current Output Output Cable Resistance PO Feedback Type BIAS INPUT INFO OUTPUT UNIT ACDC_LinkSwitch-LP_053106_Rev1-12.xls; LinkSwitch-LP Continuous/Discontinuous Flyback Transformer Design Spreadsheet RDR-83 Volts Volts Hertz Volts Amps CVCC Volts Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage (main) measured at the end of output cable (For CV/CC designs enter typical CV tolerance limit) Power Supply Output Current (For CV/CC designs enter typical CC tolerance limit) Choose "YES" from the 'CV/CC output' drop down box at the top of this spreadsheet for approximate CV/CC output. Choose "NO" for CV only output Enter the resistance of the output cable (if used) Output Power (VO x IO + dissipation in output cable) Choose 'BIAS' for Bias winding feedback and 'OPTO' for Optocoupler feedback from the 'Feedback Type' drop down box at the top of this spreadsheet Choose 'YES' in the 'Bias Winding' drop down box at the top of this spreadsheet to add a Bias winding. Choose 'NO' to continue design without a Bias winding. Addition of Bias winding can lower no load consumption Choose 'YES' from the 'clampless Design' drop down box at the top of this spreadsheet for a clampless design. Choose 'NO' to add an external clamp circuit. Clampless design lowers the total cost of the power supply Efficiency Estimate at output terminals. For CV only designs enter 0.7 if no better data available ENTER APPLICATION VARIABLES 85 265 50 7.70 0.21 YES 0.25 0.25 Ohms 1.63 Watts Bias Winding Yes Add Bias Winding YES Clampless design YES Clample ss n Z tC CIN Input Rectification Type H 0.65 0.35 2.90 9.40 0.65 0.35 Loss Allocation Factor (Secondary side losses / Total losses) mSeconds Bridge Rectifier Conduction Time Estimate UFarads Input Capacitance Choose H for Half Wave Rectifier and F for Full Wave Rectification from the 'Rectification' drop down box at the top of this spreadsheet H ENTER LinkSwitch-LP VARIABLES LinkSwitch-LP Chosen Device ILIMITMIN ILIMITMAX fSmin LNK562 LNK562 0.124 Amps 0.146 Amps 61000 Hertz Minimum Current Limit Maximum Current Limit Minimum Device Switching Frequency LinkSwitch-LP device Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 36 29-Sept-06 I^2fMIN I^2fTYP VOR VDS VD KP 0.90 90.00 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 1099 A^2Hz 1221 A^2Hz 90 Volts 10 Volts 0.9 Volts 1.99 I^2f Minimum value (product of current limit squared and frequency is trimmed for tighter tolerance) I^2f typical value (product of current limit squared and frequency is trimmed for tighter tolerance) Reflected Output Voltage LinkSwitch-LP on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.9 DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS 0.45 0.04 Amps 0.12 Amps 0.12 Amps 0.05 Amps Maximum Duty Cycle Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current 73 Volts 375 Volts Minimum DC Input Voltage Maximum DC Input Voltage TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP_TOLERANCE 3486 uHenries 10 % Typical Primary Inductance. +/- 10% Primary inductance tolerance Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 15 of 36 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand NP ALG BM BAC ur LG BWE OD INS DIA AWG CM CMA 178 110 nH/T^2 1490 Gauss 745 Gauss 1654 0.20 Mm 17.2 Mm 0.10 Mm 0.02 Mm 0.07 Mm 41 AWG 8 Cmils Primary Winding Number of Turns Gapped Core Effective Inductance 29-Sept-06 Maximum Operating Flux Density, BM<1500 is recommended AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils 150 Cmils/Amp Primary Winding Current Capacity (150 < CMA < 500) TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP ISRMS IRIPPLE CMS AWGS DIAS ODS INSS VOLTAGE STRESS PARAMETERS VDRAIN - Volts Peak Drain Voltage is highly dependent on Transformer capacitance and leakage inductance. Please verify this on the bench and ensure that it is below 650 V to allow 50 V margin for transformer variation. Output Rectifier Maximum Peak Inverse Voltage 1.30 Amps 0.47 Amps 0.42 Amps 93 Cmils 30 AWG 0.26 Mm 0.51 Mm 0.12 Mm Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness PIVS 44 Volts TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 IO1 PO1 VD1 NS1 7.7 Volts 0.211 Amps 1.63 Watts 0.9 Volts 17.00 Main Output Voltage (if unused, defaults to single output design) Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 36 29-Sept-06 ISRMS1 IRIPPLE1 PIVS1 Recommended Diodes Pre-Load Resistor CMS1 AWGS1 DIAS1 ODS1 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 0.470 Amps 0.42 Amps 44 Volts SB160, 11DQ06 3 k-Ohms 94 Cmils 30 AWG 0.26 mm 0.51 mm Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Recommended Diodes for this output Recommended value of pre-load resistor Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire 2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 Recommended Diode CMS2 AWGS2 DIAS2 ODS2 0 Cmils AWG mm mm Volts Amps 0.00 Watts 0.7 Volts 1.38 0.000 Amps 0.00 Amps 3 Volts Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Recommended Diodes for this output Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire 3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 Recommended Diode CMS3 AWGS3 DIAS3 ODS3 0 Cmils AWG mm mm Volts Amps 0.00 Watts 0.7 Volts 1.38 0.000 Amps 0.00 Amps 3 Volts Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Recommended Diodes for this output Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 17 of 36 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Total power Negative Output 1.63 Watts N/A Total Output Power 29-Sept-06 If negative output exists enter Output number; eg: If VO2 is negative output, enter 2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency 90 80 Efficiency (%) 70 60 50 40 30 50 75 100 125 150 175 200 225 250 275 300 AC Input Voltage (V) Figure 7 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz. Page 19 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 9.1.1 Active Mode ENERGY STAR / CEC Efficiency Measurement Data All single output cordless phone adapters manufactured for sale in California after July 1st, 2007 must meet the CEC requirement for minimum active mode efficiency and no-load input power. Cordless phone adapters must also meet this specification on a voluntary basis to be able to display the ENERGY STAR logo. Minimum active mode efficiency is defined as the average efficiency of 25, 50, 75 and 100% of rated output power, based on the nameplate output power: ENERGY STAR / CEC Active Mode Efficiency Specification Nameplate Output (PO) <1W 1 W to 49 W > 49 W Minimum Efficiency in Active Mode of Operation 0.49 x PO 0.09 x ln (PO) + 0.49 [ln = natural log] 0.84 x PO For adapters that are single input voltage only, the measurement is made at the rated, single nominal input voltage (115 VAC or 230 VAC). For universal input adapters, the measurement for ENERGY STAR qualification is made at both nominal input voltages (115 VAC and 230 VAC); for CEC qualification, measurements are made at 115 VAC only. 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 61.0 65.4 66.5 67.4 65.1 230 VAC 56.1 62.6 63.6 62.9 61.3 53.2 More states within the USA and other countries are adopting this standard. For the latest information, please visit the PI Green Room at: http://www.powerint.com/greenroom/regulations.htm Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 9.2 No-load Input Power The supply easily meets the ENERGY STAR / CEC and European no-load power consumption specifications of 0.5 W and 0.3 W (respectively). 0.3 0.25 Input Power (W) 0.2 0.15 0.1 0.05 0 0 50 100 150 200 250 300 AC Input Voltage (V) Figure 8 - No Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. 9.3 Available Standby Output Power The supply provides >500 mW of available output power, at an input power of 1 W. 1 0.9 0.8 Available Output Power (W) 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 50 100 150 200 250 300 AC Input Voltage (V) Figure 9 - Available Output Power at 1 Watt Input Power vs. Input Voltage. Page 21 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 9.4 Regulation 29-Sept-06 9.4.1 VI Curve vs. Input Voltage 12 10 LOWER LIMIT UPPER LIMIT 115 VAC 85 VAC 230 VAC 265 VAC Output Voltage (V) 8 6 4 2 0 0 0.1 0.2 0.3 0.4 0.5 Output Current (A) 0.6 0.7 0.8 Figure 10 - Output VI Curve, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 10 Thermal Performance 10.1 LNK562 Temperature Rise The RD-83 was installed within a sealed plastic enclosure, placed inside a sealed cardboard box, and placed into a thermal chamber at 50 C. The cardboard box prevented the chamber circulation fan from blowing air across the plastic enclosure. A thermocouple, attached to pin 2 of U1, was used to monitor its temperature. Item Ambient LinkSwitch (U1) Temperature (C) 85 VAC 50 78 265 VAC 50 84 This result indicates acceptable thermal margin of approximately of 16 C to the recommended maximum SOURCE pin temperature of 100 C 10.2 Thermal Image An infrared thermograph of the board was taken to measure the temperature of other components. This identified U1 and D4 as the highest temperature components. Using the results from the previous section, this indicates that D4 would also have an acceptable temperature rise at 50 C ambient. Figure 11 - Thermal Image of the RD-83 at Full Load, 85 VAC Input and Ambient Temperature of 22 C. Page 23 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 11 Waveforms 11.1 Drain Voltage and Current, Normal Operation Figure 12 - 85 VAC, Full Load . Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V/Div, 2 s / div. Figure 13 - 265 VAC, Full Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V/Div, 2 s / div. 11.2 Output Voltage Start-up Profile The output was loaded with a 39 resistive load. Figure 14 - Start-up Profile, 115VAC. 2 V, 20 ms / div. Figure 15 - Start-up Profile, 230 VAC. 2 V, 20 ms / div. The start-up waveforms show minimal output overshoot (<200 mV). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 11.3 Drain Voltage and Current Start-up Profile The output was loaded with a 39 resistive load and the output profile captured. These waveforms show no sign of core saturation and acceptable margin to the recommended maximum drain voltage of 650 VPK. Figure 16 - 85 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V & 1 ms / div. Figure 17 - 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V & 1 ms / div. Page 25 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 11.4 Load Transient Response (50% 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 18 - Transient Response, 115 VAC, 50-10050% Load Step. Top: Load Current, 0.1 A/div. Bottom: Output Voltage 200 mV, 500 s / div. Figure 19 - Transient Response, 230 VAC, 50-10050% Load Step. Upper: Load Current, 0.1 A/ div. Bottom: Output Voltage 200 mV, 500 uS / div. These results were significantly lower than the linear adapter where ripple and transient response variation was greater than 1 VP-P. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 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 the pickup of spurious signals. Details of the probe modification are provided in Figure 20 and Figure 21. The 5125BA probe adapter (from probe master) 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 Figure 21). Probe Ground Probe Tip Figure 20 - Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed). Figure 21 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added). Page 27 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 11.5.2 Measurement Results Figure 22 - Ripple, 85 VAC, Full Load. 5 ms, 50 mV / div (240 mVP-P). Figure 23 - Ripple, 115 VAC, Full Load. 5 ms, 50 mV / div (80 mVP-P). Figure 24 - Ripple, 230 VAC, Full Load. 5 ms, 50 mV /div (130mVP-P). Figure 25 - Ripple of a Linear adaptor, 115 VAC Input, Full Load. 2 ms, 200 mV/div (800 mVP-P). Figure 22 shows increased line frequency ripple. If required, this could be lowered to the level shown in Figure 23 by increasing the value of C6 and C1 to 4.7 F. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 12 Line Surge Differential and common mode 1.2/50 s surge testing was completed on a single test unit, to IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. The output of the supply was loaded to full load, and correct operation was verified following each surge event. Surge Level (V) +2000 -2000 +10000 -10000 Input Voltage (VAC) 230 230 230 230 Injection Location L to N L to N L,N to RTN L,N to RTN Injection Phase () 90 90 90 90 Test Result (Pass/Fail) Pass Pass Pass Pass Unit passed under all test conditions. Page 29 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 13 Conducted EMI Measurements were made with the output RTN of the supply connected to the artificial hand connection on the LISN (line impedance stabilization network) to represent worstcase conditions. The results show excellent margin of >15 dBV to both the quasi-peak and the average limit lines. Power Integrations 28.Aug 06 09:43 Att 10 dB AUTO dBV 80 RBW 9 kHz MT 500 ms PREAMP OFF Marker 1 [T1 ] 28.50 dBV 182.849162999 kHz 10 MHz 70 1 QP CLRWR 2 AV CLRWR 1 MHz LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG SGL EN55022Q 60 EN55022A 50 TDF 40 30 1 20 10 0 -10 -20 150 kHz 30 MHz Figure 26 - Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 36 29-Sept-06 Power Integrations 28.Aug 06 09:53 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand RBW 9 kHz MT 500 ms PREAMP OFF Marker 1 [T1 ] 28.76 dBV 182.849162999 kHz 10 MHz Att 10 dB AUTO dBV 80 70 1 QP CLRWR 2 AV CLRWR 1 MHz LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG SGL EN55022Q 60 EN55022A 50 TDF 40 30 1 20 10 0 -10 -20 150 kHz 30 MHz Figure 27 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits. Page 31 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 14 Revision History Date 29-Sept-06 Author JAC Revision 1.0 Description & changes Initial Release Reviewed PV, JJ, DA Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Notes Page 33 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Notes 29-Sept-06 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 36 29-Sept-06 RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand Notes Page 35 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-83 7.7 V, 210 mA Adapter with 10 kV surge withstand 29-Sept-06 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. (c)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: usasales@powerint.com GERMANY Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3910 Fax: +49-89-5527-3920 e-mail: eurosales@powerint.com 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: japansales@powerint.com KOREA RM 602, 6FL Korea City Air Terminal B/D, 159-6 Samsung-Dong, Kangnam-Gu, Seoul, 135-728, Korea Phone: +82-2-2016-6610 Fax: +82-2-2016-6630 e-mail: koreasales@powerint.com SINGAPORE 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com 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: taiwansales@powerint.com CHINA (SHANGHAI) Rm 807-808A, Pacheer Commercial Centre, 555 Nanjing Rd. West Shanghai, P.R.C. 200041 Phone: +86-21-6215-5548 Fax: +86-21-6215-2468 e-mail: chinasales@powerint.com INDIA 261/A, Ground Floor 7th Main, 17th Cross, Sadashivanagar Bangalore, India 560080 Phone: +91-80-41138020 Fax: +91-80-41138023 e-mail: indiasales@powerint.com UNITED KINGDOM 1st Floor, St. James's House East Street, Farnham Surrey, GU9 7TJ United Kingdom Phone: +44 (0) 1252-730-140 Fax: +44 (0) 1252-727-689 e-mail: eurosales@powerint.com CHINA (SHENZHEN) Room 2206-2207, Block A, Elec. Sci. Tech. Bldg. 2070 Shennan Zhong Rd. Shenzhen, Guangdong, China, 518031 Phone: +86-755-8379-3243 Fax: +86-755-8379-5828 e-mail: chinasales@powerint.com ITALY Via De Amicis 2 20091 Bresso MI - Italy Phone: +39-028-928-6000 Fax: +39-028-928-6009 e-mail: eurosales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 APPLICATIONS FAX World Wide +1-408-414-9760 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 36 |
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