You are on page 1of 2

DI-158 Design Idea

®
LinkSwitch-II

5 W Charger/Adapter

Application Device Power Output Input Voltage Output Voltage Topology


Charger/Adapter LNK616PG 5W 85 – 265 VAC 5V Flyback

Design Highlights In this design diodes D1 through D4 rectify the AC input. Capaci-
• Revolutionary control concept enables very low cost, low part- tors C1 and C2 filter the rectified AC. Inductors L1 and L2, with
count solution capacitors C1 and C2 form pi (π) filters to attenuate conducted
• Primary-side control eliminates secondary-side controller and differential-mode EMI. This, in combination with Power
optocoupler Integrations’ transformer E-sheild™ technology, means EMI
• Constant voltage (CV) accuracy: ±5% standard EN55022 class B compliance with wide margin, using no
• Constant current (CC) accuracy: ±10% Y capacitor. Fusible, flameproof, wire-wound resistor RF1 provides
• Over-temperature protection with hysteretic recovery ensures protection against catastrophic failure and limits inrush currents
safe PCB temperatures under all conditions during start-up.
• Auto-restart: output short circuit and open-loop protection
• Highly energy efficient Figure 1 shows U1 biased from an optional bias supply, which
• Average efficiency over load range: 74% reduces no-load power consumption and improves efficiency
(vs. the 67% Energy Star 2.0 requirement) when driving light loads. Capacitor C4 provides decoupling of U1
• No-load input energy consumption: <50 mW at 230 VAC and its value selects the amount of cable-drop compensation.
• Easily meets the following specifications:
• EN55022 and CISPR-22 Class B EMI (>10 dB margin) In the CV region, the output voltage is regulated by using ON/OFF
• IEC 61000-4-5 Class 3 AC line surge and IEC61000-4-2 ESD control, and is maintained by skipping switching cycles. Regula-
withstand to ±15 kV. tion is maintained by adjusting the ratio of enabled to disabled
switching cycles. This also optimizes the efficiency of the con-
Operation verter over the entire load range by scaling switching losses with
The schematic in Figure 1 depicts the design for a 5 W universal output load. At light loads (trickle charge) the primary current limit
input, constant voltage/constant current (CV/CC) charger power- is reduced to decrease the transformer flux density, which
supply design based on Power Integrations’ LinkSwitch-II family minimizes audible noise. As the load current increases, the current
product LNK616PG. This design is useful for battery chargers for limit is increased and fewer and fewer cycles are skipped.
cell phones, USB chargers, or any applications requiring a CV/CC
characteristic. C6
R8 2.2 nF
100 7 50 V
L1 T1
1.5 mH EE16 5 V, 1 A

C3 1 10
R3 D7
1 nF SL44 C7 C8
1 kV 470 k7 R9
R1 470 MF 470 MF 1.2 k7
D1 D2 10 k7 10 V 10 V
1N4007 1N4007 8
R4 4
300 7 RTN
5
D5
RF1 1N4007
10 7
2W 3

C1 C2
4.7 MF 10 MF 2
85 - 265 400 V 400 V
VAC

NC
LinkSwitch-II
U1 D6* R5
R2 LL4148 14.7 k7
10 k7 LNK616PG
D
1%
D3 D4 FB
1N4007 1N4007
BP

S
C4 R7* R6
6.2 k7 C5* 9.76 k7
1 MF 10 MF
L2 25 V 5% 1%
1.5 mH 16 V

*Optional components PI-5133-050808

Figure 1: 5 W CV/CC Universal Input Charger Power Supply.

www.powerint.com May 2008


When no switching cycles are skipped (maximum output power • Space the AC input away from switching nodes to minimize
point) the controller within the LinkSwitch-II transitions into CC noise coupling that may bypass input filtering.
mode. A further increase in the demand for load current causes • The extended creepage distance on U1 between the high and
the output voltage to drop. The drop in output voltage is reflected low voltage pins prevents arcing and improves reliability,
on the FB pin voltage. In response to the reduction of voltage at especially important in very humid conditions.
the FB pin, the switching frequency is reduced to achieve a linear • Use 1% tolerance resistors for R5 and R6 for better output
CC output. The RCD-R clamp formed by D5, R3, R4, and C3 accuracy.
limits leakage inductance drain voltage spikes. Resistor R4 has a
relatively large value to prevent ringing on the drain voltage 80

PI-5143-050708
waveform caused by the leakage inductance. This improves
70
regulation and reduces EMI generation.
60
Diode D7 rectifies the secondary and C7 filters it. The combination
of C6 and R8 limits transient voltage spikes across D7 and 50
reduces conducted as well as radiated EMI. Resistor R9 acts as 40

dBµV
an output preload to ensure the output voltage at no-load is within
acceptable limits. Feedback resistors R5 and R6 set both the 30
maximum operating frequency (and thereby the output current) in 20
the CC region and the output voltage in the CV region.
10
Key Design Points
0
• Capacitor C7 and C8 were chosen as a low ESR type capaci-
tors to meet the output voltage ripple requirement without LC -10
post filtering.
-20
• If lower average efficiency is acceptable (3% to 4% drop), 0.15 1.0 10.0 100.0
replace D7 with a PN-junction diode to lower cost. Then re-
MHz
adjust R5 and R6 as needed to ensure the output voltage stays
Figure 3. Conducted EMI, EN55022 B Limits: Measurements Made at 230 VAC
centered. with Output Connected to Earth Ground .
• Place C4 physically close to U1 on the PCB.
• Minimize clamp and output diode loop areas for reduced EMI.
Transformer Parameters
6 EE16, NC-2H or equivalent, gapped for ALG of
PI-5142-051608

Core Material
88.55 nH/t²
5 Bobbin EE16, Horizontal, 10 pins, (5/5)
Output Voltage (VDC)

Shield: 15T x 3, 35 AWG


4 Minimum Limit Maximum Limit Primary: 105T, 35 AWG
85 VAC, 40 °C 115 VAC, 40 °C
230 VAC, 40 °C 265 VAC, 40 °C Winding Details 1st Half Bias: 6T x 4, 30 AWG
85 VAC, 25 °C 115 VAC, 25 °C 2nd Half /Feedback: 6T x 4, 30 AWG
3 230 VAC, 25 °C 265 VAC, 25 °C
85 VAC, 0 °C 115 VAC, 0 °C Secondary: 7T, 22 TIW
230 VAC, 0 °C 265 VAC, 0 °C
2 Shield (2–NC), Primary (4–1), Bias (5–3),
Winding Order
Feedback (3–2), 5 V (10–8)

1 Primary Inductance 1.074 mH, ±10%


Primary Resonant 1000 kHz (minimum)
Frequency
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Leakage
Inductance 95 μH (maximum)
Output Current (mA) Table 1. Transformer Parameters. (AWG = American Wire Gauge,
Figure 2. Typical CV/CC Characteristic Over Line and Temperature. TIW = Triple Insulated Wire, NC = No Connection)

Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com 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, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2008, Power Integrations, Inc.

A
05/08 DI-158

You might also like