Design of 5V@4A Adaptor with INN2125K (InnoSwitch-CE) · PDF fileAmbient Temprature T AMB ......
Transcript of Design of 5V@4A Adaptor with INN2125K (InnoSwitch-CE) · PDF fileAmbient Temprature T AMB ......
Page 1©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
Design of 5V@4A Adaptor with
INN2125K (InnoSwitch-CE)
RL – PI China Office
6 Nov, 2015 (Rev-1)
Page 2©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
• Integrated-Secondary Side Regulation for Fast DLR;
• Complete System and Output Protections (SCP, OPP, OCP, OVP, OTP);
• Build in Secondary Sync-Rectification; Efficiency Ratings exceeded DoE &
CoC_v5.0;
• Exceptional CV/CC accuracy independent of transformer design or external
components tolerances.
Design Features :
Page 3©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
1. Power Supply Specification
Description Symbol Min Typ Max Units Comment/Conditions
Voltage VIN
90 265 VAC 2 Wire no P.E.
Frequency fLINE
47 50/60 63 Hz
No-load Input Power PIN
30 mW Input 230 VAC
Output Voltage VOUT
4.75 5.0 5.25 V Measured at the End of cable
Output Current IOUT
4 A
Output Ripple Voltage VRIPPLE 100 mVP-P Measured at the End of cable, 20 MHz Bandw idth
Total Output Power
Continuous Output Power POUT 20 W
Peak Output Power POUT_PK W
Conducted EMI Margin 6 dB CISPR22B/EN55022 class B
Average Efficiency η 83.1 % measure at PCB end
Ambient Temprature TAMB
0 40 Free convection, sea level
Surge Test kV Differential Mode:2ΩΩ
ESD(Air Discharge) kV On each output terminals; +/-Ω
Safety
OUTPUT
INPUT
Designed to meet IEC950,
UL1950 Class II
Page 4©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
2. Schematic
EC3
10uF400 V
L2
300uH
R5
300K
5V Output
Ilimit = 950mA
CY1 470pF
R9
47R
C160.1uF
EC4
10uF400 V
R347R
C7 2.2nFUSB1
2
4
1
3
C3
10uF
C8
2.2uF
C17
1000uF
6.3V
D3 SS1060FL
D4
RS
1M
L
R447R
C8
1000uF
6.3V
T1RM8
D2M7
S
D
BP
FW
D
SR
/P
BP
S
VO
GN
D
FB
ISU1
INN2125
R11
91KR7 10R
C61nF1KV
-+
BD1
ABS210
Q1 AO4260R10 30K
F1
T2L
/25
0V
N
LF3
25uH
L
EC1
10uF
400 V
t
RT15D-7
EC2
10uF400 V R2
22R
R16.8K D1
12V
R1713mR
R1913mR
USB2
2
4
1
3
Page 5©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
3. BOM
I tem Qty C/C Reference Des cription
1 1 BD1 ABS210, 2A 1000V Rectifier, ABS
2 1 C16 100nF,16V, Cera mic, X7R, 0805
3 1 C3 10uF,25V, 1206
4 1 C6 1nF,250V,Cera mic,X7R,0805
5 1 CY1 Y-Ca p,Y1,470pF
6 1 D2 S1ML,Recti fier,1A, 1000V, SOD-123
7 1 D4 RS1DL,Fa st Recovery,0.8A, 200V, SOD-123
8 4 EC1,EC2,EC3,EC4 10uF,400 V, Electrolyti c, (8X12)
9 1 F1 2A 250V,Time-la g Fus e
10 1 L1 25uH,Common choke, 0.2mm, 9T, T6*3*2 Core
11 1 LF3 300uH,Axia l , I-Core, 6 x 10
12 1 PCB FR-4
13 1 R1 6.8K,5%,Thick Fi lm,0603
14 1 R2 51R,5%,Thick Fi lm, 1206
15 2 R3,R4 300K,5%,Thick Fi lm, 1206
16 1 R5 22R,5%,Thick Fi lm,0603
17 1 RT1 NTC,5D-7
18 1 T1 RM8,6+6Pin
19 1U1
SC2125K, eSOP-R16B (or K-package), I-Limi t =
950mA, 100kHz
20 1 ZD1 12V, 5%, Zenner, SOD-80
23
Primary Side Components
Item Qty C/C ReferenceDes cription
1 2 EC8, EC171000uF,6.3V, Sol id Ca p, (8X11.5)
2 1 C8 2.2uF,16V, Cera mic, X5R, 0805
3 1 C7 2.2nF,100V, Cera mic, X7R, 0805
4 1 R11 91K,1%,Thi ck Fi lm,0603
5 1 R10 30K,1%,Thi ck Fi lm,0603
6 1 R9 47R,5%,Thick Fi lm,0603
7 1 R7 10R,5%,Thick Fi lm,0805
8 2 R17,R19 13mR,1%,metal s tri p type,0805
9 1 D3 SS1060FL,60V,1A,Schottky,SOD-123
10 1 Q1 AO4260, Mos fet, 60V,18A,6.3mR, SO-8
12
Secondary Side Components
Page 6©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
4. Demo Board
SC2125K (U1)
AO4260(SR FET, Q1)
(Component height on the PCB surface is 18mm)
Page 7©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
5. Transformer DesignSCHEMATIC
MATERIALS:
1. Core : RM8 (TDK PC95 or equivalent, Ae = 64mm2)
2. Bobbin : RM8 (6+6pin).
3. Magnet Wires (Primary) : Type 2-UEW
4. Magnet Wire (Secondary) : Triple Insulated Wires
ELECTRICAL SPECIFICATIONS:
1. Primary Inductance (Lp) = 690uH ± 7% @ 10KHz
2. Primary Leakage Inductance < 20uH
3. Electrical Strength = 3KV, 50/60Hz,1Min
FINISHED :
1. Varnish the assembly completely
Wire started in clockwise direction from pin-2 and ended at pin-11 when
looking from the bottom side of the bobbin in a “Clockwise” Direction.
Triple Insulated Wire (Clockwise)0.55 mmx3__3T – Secondary
2UEW 0.4 mmx1__19.5T – Primary (Clockwise)2(S)
A(S)
TOP
2T Tape
2T Tape
BOTTOM
5(S) 2UEW 0.25 mmx5__6T – Bias (Clockwise)
4(F)
7(F)1T Tape
2UEW 0.4 mmx1__18.5T – Primary (Clockwise)
B(F)
7(S)
1(F)2T Tape
X(S) 2UEW 0.25 mmx6__4T – Shield (Clockwise)
1T Tape1(F)
Secondary
3T
B
A
Primary
38T
5Bias
6T
Shield
4T
4
1
x
2
1
719.5T
18.5T
Note: Core is connected to PIN-1
2 1
45
11
Page 8©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
6a. Regulation, Ripple, EfficiencyNote: Output voltage is measured between Output E-Cap (+) and INNO’s (Is) – To eliminate voltage drop induced by USB connector.
VIN PIN VOUT IOUT VRIPPLE POUT η Average DOE
(VAC) (W) on PCB(V) (mA) (mVP-P) (W) (%) η(%) η (%)
0.007 5.01 0 15
23.470 5.18 4000 30 20.72 88.28
17.480 5.15 3000 66 15.44 88.34
11.530 5.11 2000 82 10.21 88.55
5.708 5.06 1000 80 5.06 88.65
0.007 5.01 0 20
23.330 5.18 4000 32 20.72 88.81
17.350 5.15 3000 62 15.45 89.05
11.440 5.11 2000 66 10.21 89.28
5.670 5.06 1000 74 5.06 89.24
0.011 5.01 0 18 0 0
23.440 5.20 4000 30 20.78 88.67
17.400 5.15 3000 64 15.45 88.79
11.470 5.11 2000 72 10.22 89.10
5.685 5.06 1000 72 5.06 89.01
0.013 5.01 0 20 0 0
23.530 5.20 4000 36 20.78 88.33
17.490 5.15 3000 66 15.45 88.34
11.530 5.11 2000 74 10.22 88.64
5.710 5.07 1000 60 5.07 88.70
264
90
230
115
83.08
88.45
88.89
89.10
88.50
Page 9©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
6.b Regulation, Ripple, EfficiencyNote: Output voltage is measured on USB ends (Connect both USBs in parallel).
VIN PIN VOUT IOUT VRIPPLE POUT η Average DOE
(VAC) (W) on PCB(V) (mA) (mVP-P) (W) (%) η(%) η (%)
0.007 5.01 0 15
23.500 5.11 4000 30 20.44 86.98
17.460 5.10 3000 66 15.29 87.54
11.520 5.07 2000 82 10.14 88.02
5.695 5.05 1000 80 5.05 88.60
0.007 5.01 0 20
23.330 5.12 4000 32 20.48 87.78
17.350 5.10 3000 62 15.30 88.18
11.450 5.07 2000 66 10.14 88.56
5.666 5.05 1000 74 5.05 89.08
0.011 5.01 0 18 0 0
23.440 5.13 4000 30 20.52 87.54
17.400 5.10 3000 64 15.30 87.93
11.480 5.08 2000 72 10.16 88.50
5.690 5.05 1000 72 5.05 88.73
0.013 5.01 0 20 0 0
23.530 5.13 4000 36 20.53 87.24
17.470 5.10 3000 66 15.30 87.58
11.530 5.08 2000 74 10.16 88.08
5.720 5.05 1000 60 5.05 88.29
83.08
87.79
88.18
88.40
87.80264
90
230
115
Page 10©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
7. Dynamic Load Response (measured on PCB end)
CH1: Output Voltage, 1V/Div,
CH4: Output Current, 2A/Div
Test Conditions:
1. AC input = 90VAC
2. Load range: 0A-4.0A-0A
3. Frequency: 100Hz(5ms/5ms)
4. Slew rate: 0.5A/uS
CH1: Output Voltage, 1V/Div,
CH4: Output Current, 2A/Div
Test Conditions:
1. AC input = 264VAC
2. Load range: 0A-4.0A-0A
3. Frequency: 100Hz(5ms/5ms)
4. Slew rate: 0.5A/uS
0A
4.0A
0A
4.0A
5.09V
4.87V
5.38V
4.87V
5.38V
Page 11©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
8. Maximum Drain Voltage
Test Conditions During Start-up, Full Load.
VIN=264VAC, Iout=4A
Measured Results
Vdrain_max = 517V
% Derating = 517V/650V =79.5% (< 90%)
Page 12©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
Test Conditions :
1. During Start-up, VIN=264VAC, Iout=4A.
a) SR-FET (Q1) = AO4260@18A/60V;
b) Parallel Diode (D3) : SS1060 @1A/60V
Measured Results:
VPIV_max = 50.2V
% Derating = 51.7V/60V = 86.17% (< 90%)
9. Output Rectifier Maximum Inverse Voltage
Page 13©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
10. Conducted Emission – PK and AV (Output Float, Resistive load)
PK
AV
PK
AV
PK
AV
PK
AV
115Vac input
Live
230Vac input
Live
115Vac input
Neutral
230Vac input
Neutral
Page 14©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
11a. Radiated Emission
110V AC input
Page 15©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
11b. Radiated Emission
230V AC input
Page 16©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
12. Temperature Rise Test
Measurment Point Input:90Vac Load:4.0A Input:264Vac Load:4.0A
Components Temperature() Temperature()
1 T-Ambient 40.0 40.0
2 U1(INN2125K) 85.5 84.9
3 Core (Transformer) 82.0 84.5
4 Winding (Transformer) 82.0 84.2
5 Q1, SR-MOSFET (AO4260) 87.7 89.8
6 C17, Solid-Ecap 1000uF 6.3V 82.5 84.0
7 EC4,primary Bulk Cap 83.9 80.7
8 Case, close to U1 72.5 72.6
Testing Conditions and Setup :
a) Perform under a controlled temperature chamber;
b) PCB is being mounted inside an enclosure and attach with a copper heat spreader
c) Thermal coupler (type-K) are attached to respective measuring points;
d) Temperature is recorded after 1 hours from initial turn on.
A Heat-Spreader is used to spread heats out from the enclosure.
The heat conductor (Al or Cu) should cover the InnoSwitch and SR-FET.
Plastic Enclosure
Page 17©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
13. Heat-Spreader Assembly and Process
Silicon Glues(Min. 5 c.c. is to be applied in these area)
Heat-Spreader
(Materials : 0.3mm Copper Foil)
PCB Completed Final
Testing
Apply Silicon Glues
at INNO and SR-FET
Apply Heat-Spreader
on designated PCB
location
Hand Solder Ground
Terminal (If present)
Insert Heat-Spreader
Assembly into
Housing
33 mm
40 mm
33 mm
40 mm
28 mm
35 mm
3.5 mm (x2)
13 mm (x2)
Insulation Sheet
(Materials : Mylar, 0.43mm UL®)
Location of Insulation
Sheet
Silicon Glues(Min. 15 c.c. is to be applied in these area)
Page 18©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
14. ESD Test
Contact Discharge Air Discharge
Level Test Voltage (KV) Level Test Voltage (KV)
1 2 (Pass) 1 2 (Pass)
2 4 (Pass) 2 6 (Pass)
3 6 (Pass) 3 8 (Pass)
4 8 (Pass) 4 15 (Pass)
- 18 (Pass)
Page 19©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
15. Product Feature INNO-CP & other Components
(Q1, SR-FET)
Page 20©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
16. Product Feature – Silicon Glue (Adhesive for Heat-Sinking)
Page 21©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
17. Document Change History
Revision History
Date Author Revision Description & changes Reviewed
9-Nov-2015 RL Rev-1 First Released EH QUEK
Page 22©2015 Power Integrations | www.power.com COMPANY CONFIDENTIAL
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time to improve reliability or manufacturability.
Power Integrations does not assume any liability arising from the use of any
device or circuit described herein.
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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
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Integrations’ patents may be found at www.powerint.com.
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set forth at http://www.powerint.com/ip.htm
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