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Design Example Report
Title Specification Application Author Document Number Date Revision 3W Wide Range Flyback Power Supply using LNK304P Input: 57-580VAC Output: 12V / 250mA Utility Meter Power Integrations Applications Department DER-58 May 4, 2005 1.0
Summary and Features * * * * * * * * StackFETTM Flyback Topology delivers full load over extremely wide input AC voltage range LinkSwitch-TN feedback simplifies non-isolated voltage regulation - 2 resistors precisely set the output voltage E-SHIELDTM Transformer Construction for reduced common-mode EMI (>10dB margin) 66kHz Switching Frequency with jitter to reduce conducted EMI Simple ON/OFF controller - no feedback compensation required Auto-restart function for automatic and self-resetting open-loop, overload and shortcircuit protection Built-in Hysteretic thermal shutdown at 135C EcoSmart for extremely low standby power consumption <200mW at 265VAC
The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com.
Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-58
Wide-range Flyback using LNK304
May 4, 2005
Table Of Contents
1. Introduction .................................................................................................................... 3 2. Power Supply Specification ........................................................................................... 4 3. Schematic ...................................................................................................................... 5 4. Circuit Description.......................................................................................................... 6 5. PCB Layout.................................................................................................................... 7 6. Bill Of Materials.............................................................................................................. 8 7. Transformer Specification .............................................................................................. 9 7.1. Transformer Electrical Diagram ..................................................................................... 9 7.2. Electrical Specifications ................................................................................................. 9 7.3. Materials ........................................................................................................................ 9 7.4 Transformer Build Diagram.......................................................................................... 10 7.5 Transformer Construction ............................................................................................ 10 7.6 Design Notes ............................................................................................................... 11 8. Transformer Spreadsheets .......................................................................................... 12 9. Performance Data........................................................................................................ 13 9.1. Efficiency and Standby Power Consumption ............................................................... 13 9.2. Regulation.................................................................................................................... 14 10. Waveforms................................................................................................................... 15 10.1. Drain Voltage and Current, Normal Operation ......................................................... 15 10.2. Output Voltage Start-up Profile at Full Load............................................................. 15 10.3. Drain Voltage and Current Start-up Profile............................................................... 16 10.4. Load Transient Response at 120VAC (50% to 100% Load Step) ............................ 17 10.5. Output Ripple Measurements................................................................................... 18 10.5.1. Ripple Measurement Technique........................................................................... 18 10.5.2. Measurement Results at Full Load ....................................................................... 19 11. Conducted EMI ............................................................................................................ 20 Revision History...................................................................................................................... 21 Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
1. Introduction
This document is an engineering report describing a wide-range non-isolated StackFET(R) Flyback converter employing the LNK304P. The document contains the power supply specification, schematic, bill-of-materials, transformer documentation, printed circuit layout, and performance data. +12VDC
AC Input GND
Figure 1 - Populated Circuit Board Photograph
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
2. Power Supply Specification
Description Input Voltage Frequency No-load Input Power (240 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Efficiency Environmental Conducted EMI Safety
Meets CISPR22B / EN55022B Class I (non-Isolated)
Symbol VIN fLINE
Min 57 47
Typ
Max 580 64 0.2
Units VAC Hz W V mV A W %
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 POUT
12 0.25 3 45
5% 20 MHz Bandwidth
Measured at POUT (3 W), 25 oC
Ambient Temperature
TAMB
0
60
o
C
Free convection, sea level
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
3. Schematic
Figure 2 -Schematic
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Page 5 of 22
DER-58
Wide-range Flyback using LNK304
May 4, 2005
4. Circuit Description
RF1 is a fusible link resistor, which limits inrush current through the full-bridge rectifier comprised of D1 to D8. This resistor also complies with safety agency requirements to blow open in the event of a catastrophic failure in the power supply. AC voltage is rectified through the full-bridge rectifier stage and filtered to produce a DC voltage across the series stacked high voltage electrolytic capacitors C1-C4. R1, R2 and R3, R4 help maintain voltage equalization across the series connected capacitors C1, C2 and C3, C5 respectively. L1, C1-C4 forms an input pi filter to reduce components of the switching frequency and its harmonics on the input line. The rectified high voltage DC is applied to the transformer (T1) primary. The other end of the transformer primary winding is connected to a high-voltage (600V) MOSFET (Q1) that is cascode connected to the Drain of the LinkSwitch-TN Switch (U1). In this configuration the effective Drain-Source voltage rating of the primary is 1300Vpk. D9-D11 clamps the maximum drain-source voltage across the LinkSwitch-TN (U1) to below 600V. D14 ensures that the maximum gate-source voltage of Q1 does not exceed 15V. R5 and R6 provide bias to enhance the gate of Q1 when its source is switched low by the drain of U1. D12, D13 and R8 clamp the leakage inductance spike to limit the effective VDS (voltage across Q1 and U1) to about 980Vpk at high line (580VAC) input. C5 is the VCC storage capacitor for U1; this capacitor is charged to 5.8V from the internal high voltage current source, U1 derives its bias from this capacitor. D15 and C7 rectify and filter the AC waveform produced from the transformer secondary winding to produce the desired DC voltage level. R10 and R11 form a potential divider that controls the output voltage. The midpoint of this divider is connected to the EN pin of U1 that is internally set at 1.63VDC. The simple ON/OFF controller integrated in the LinkSwitch-TN series switches the internal 700V MOSFET at 66kHz to maintain the output voltage set point. C8 is added across R11 to increase noise immunity in the event of transients caused by the load. The transformer was wound with shields to counteract common-mode displacement currents generated by the windings in the transformer (ESHIELDTM). This technique helps reduce conducted EMI and the burden on the input EMI filter. The primary winding was also wound with a Z-winding technique to reduce its self-capacitance and switching losses in the converter.
Page 6 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
5. PCB Layout
Figure 3 - Printed Circuit Layout
Page 7 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
6. Bill Of Materials
Item QTY 1 2 3 4 2 1 Ref Des C1, C2, C3, C4 C5, C8 C7 D1, D2, D3, D4, D5, D6, D7, D8, D13 D9, D10, D11 D12 D14 D15 J4 L1 Q1 R1, R2, R3, R4 R5, R6 R7 R8 R10 R11 RF1 T1 U1 Value 22uF/450V 0.1uF 100uF/25V Manufacturer Part Number
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
9 3 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1
Stand. Rec. 1A/1000V TVS 180V TVS 150V Zener 15V Ultrafast 1A/200V JUMPER 1mH Toko N-Chan. MOSFET 1A/600V International Rectifier 470k 1/2W 1M 1/2W 10 ohm 200 ohm 13k 1% 2.05k 1% 10R 3W EE13 Transformer PWM + MOSFET Power Integrations
1N4007GP P6KE180A P6KE150A 1N4744A UF4004 8RB-102Y IRFU1N60A
LNK304P
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
7. Transformer Specification
7.1. Transformer Electrical Diagram
Figure 4 -Transformer Electrical Diagram
7.2.
Electrical Specifications
60Hz 1minute, from Pins 1-4 to Pins 7-8 All windings open All windings open L12 with pins 7-8 shorted N/A 2.7mH +/- 10% 500 kHz min. 100H max.
Electrical Strength Primary Inductance (Pin 1 to Pin 2) Resonant Frequency Primary Leakage Inductance
7.3.
Materials Item Description [1] Core: EE13, TDK Gapped for AL = 57 nH/T2 [2] Bobbin: Horizontal 8 pins [3] Magnet Wire: #36 AWG [4] Magnet Wire: #39 AWG [5] Magnet Wire: #31 AWG [6] Tape: 3M 1298 Polyester Film (white) 0.311" x 2 mils [7] Varnish
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Page 9 of 22
DER-58
Wide-range Flyback using LNK304
May 4, 2005
7.4
Transformer Build Diagram
Figure 5 - Transformer Build Diagram
7.5
Transformer Construction
Start at pin 6 temporarily. Wind 30 turns of item [3] from left to right uniformly without any space between turns, in a single layer across the entire width of the bobbin. Finish on Pin 4. Move the start end from pin 6 to pin 3. Add 4 layers of tape [6] for insulation. Start at pin 2. Wind 55 turns of item [4] from right to left. After finishing the first layer, return to the right and add one layer of tape [6]. Then wind 55 turns of item [4] from right to left, after finishing the second layer, return to the right and add one layer of tape [6]. Then wind 54 turns of item [4] from right to left, after finishing the second layer, return to the right and add one layer of tape [6]. Again, wind 54 turns of item [4] from right to left, after finishing the fourth layer, return to the right and finish on Pin 1. Wind all layers uniformly without any spaces between the turns. Add 3 layers of tape [6] for insulation. Start of pin 1, wind 3 turns of quadfilar item [5]. Wind from right to left in a single layer across 60% of the bobbin width. Cut the wires after finishing the third turn. Add 1 layer of tape [6] for insulation. Temporarily start at pin 3. Wind 30T of item [3] from right to left in a single layer without any spaces between adjacent turns, across the entire width of the bobbin, finish on pin 7. Then move the Start lead to pin 8. Add 2 layers of tape [6] for insulation. Use guidelines specified in AN-24 for audio noise suppression techniques in the transformer construction.
W1 (Core Cancellation Winding) Insulation W2 (Primary Winding)
Insulation W3 (Shield Winding) Insulation W4 (Secondary Winding)
Outer Insulation Final Assembly
Page 10 of 22
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DER-58 7.6 Design Notes
Wide-range Flyback using LNK304
May 4, 2005
Power Integrations Device Frequency of Operation Mode Peak Current Reflected Voltage (Secondary to Primary) Maximum AC Input Voltage Minimum AC Input Voltage
LNK304P 66 KHz Continuous/ discontinuous 0.23 A 92V 580 V 57 V
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
8. Transformer Spreadsheets
Page 12 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
9. Performance Data
9.1. Efficiency and Standby Power Consumption
70% 60% 50%
Efficiency (%)
280 240 200 160 120 80 Standby Power Consumption (mW) 40 0 300
40% 30% 20% 10% 0% 0 50 100 150 200 250 Input AC Voltage (VAC)
Figure 6 - Efficiency and Standby Power Consumption vs. Input Voltage, Room Temperature, 60 Hz
Page 13 of 22
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DER-58 9.2. Regulation
Wide-range Flyback using LNK304
May 4, 2005
14
Vin = 57VAC
13.5
Vin = 85VAC Vin = 120VAC
13
Vin = 240VAC Vin = 265VAC
Output Voltage (VDC)
12.5
12
11.5
11
10.5
10 0 50 100 150 Load Current (m A) 200 250 300
Figure 7 -Load Regulation, Room Temperature.
Page 14 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
10.
10.1.
Waveforms
Drain Voltage and Current, Normal Operation
Figure 8 - 57VAC, Full Load (LNK304) Upper: IDRAIN, 0.1 A / div Lower: VDRAIN, 100 V, 20 s/div
Figure 9 - 265VAC, Full Load (LNK304) Upper: IDRAIN, 0.1 A / div Lower: VDRAIN, 200 V / div, 20 s/div
10.2.
Output Voltage Start-up Profile at Full Load
Figure 10 - Start-up Profile +12V @ 250mA 120VAC/60Hz 2V/div, 10msec/div.
Page 15 of 22
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DER-58 10.3.
Wide-range Flyback using LNK304 Drain Voltage and Current Start-up Profile
May 4, 2005
Figure 11 - 57 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div (LNK304) Lower: VDRAIN, 100 V & 1 ms / div.
Page 16 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
10.4. Load Transient Response at 120VAC (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 12 - Transient Response +5V, 50%-100%-50% Load Step. Load Current, 100mA/div. Output Voltage 1V, 2ms / div. (+12V Offset)
Page 17 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
10.5. Output Ripple Measurements 10.5.1. 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 13 and Figure 14. 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 13 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 14 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
Page 18 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
10.5.2.
Measurement Results at Full Load
Figure 15 +12V Ripple @ 57VAC 2ms, 200 mV / div
Figure 16 +12 V Ripple @ 265VAC 2 ms, 200 mV / div
Page 19 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
11. Conducted EMI
A conducted EMI scan of the prototype was taken to determine the effectiveness of the input pi-filter and transformer ESHIELDTM construction. The following plots show the peak performance of the converter against quasi-peak (QP) and average (AVG) limits of EN55022 Class B. Both scans were taken at 120VAC/60Hz input with maximum load applied to the output (250mA). Since the peak scan is below the average limits, it is expected that the QP and Average scans would have greater than 10db of margin below the limits.
Figure 17 - Conducted EMI (Neutral)
Figure 18- Conducted EMI (LINE)
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
Revision History
Date May 4, 2005 Author RSP Revision 1.0 Description & changes Initial Release Reviewed VC /JC / AM
Page 21 of 22
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DER-58
Wide-range Flyback using LNK304
May 4, 2005
Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES 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 circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
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