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STD1LNK60Z-based Cell Phone Battery Charger Design
This application note Ringing Choke Converter (RCC)-based, step-by-step cell phone battery charger design procedure. essential self-oscillating fly-back converter, operates within Discontinuous Conduction Mode (DCM) Continuous Conduction Mode (CCM) boundaries without noticeable reverse recovery output rectifying diodes. control achieved using discrete components control peak current mode, overall cost relatively compared conventional Pulse Width Modulation (PWM) fly-back converter. result, widely used power applications industry home appliances simple cost-effective solution. Figure STD1LNK60Z-based Printed Circuit Board
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September 2005
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AN2228 APPLICATION NOTE
Table Contents
Power Transformer Design Calculations
Switching Frequency STD1LNK60Z MOSFET Turn Ratio Primary Current Primary Inductance Magnetic Core Size Primary Winding Secondary Winding Auxiliary Winding Length
STD1LNK60Z-based Control Circuit Components
MOSFET Startup Resistor Optocoupler Power Methods Sense Resistor Constant Power Control Zero Current Sense Constant Voltage Constant Current
Test Results Appendix STD1LNK60Z-based Circuit Schematics Appendix STD1LNK60Z-based Circuit Bill Materials
Revision History
2/26
AN2228 APPLICATION NOTE
Figures
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure STD1LNK60Z-based Printed Circuit Board Optocoupler Fly-back Power Optocoupler Forward Power Current Sense Circuit Curve 110VAC Curve 220VAC Drain Source Voltage Operation Waveform, 85VAC Drain Source Voltage Operation Waveform, 110VAC. Drain Source Voltage Operation Waveform, 220VAC. Drain Source Voltage Operation Waveform, 265VAC. Control Circuit Components Schematic (see Section page STD1LNK60Z-based Schematic (full view)
3/26
AN2228 APPLICATION NOTE
Tables
Table Table Table Table Line Load Regulation Efficiency Ratings Standby Power
4/26
AN2228 APPLICATION NOTE
Power Transformer Design Calculations
Power Transformer Design Calculations
specifications: 85~265V 0.4A 1.2I 4.8A Line frequency: 50~65Hz
Taking transient load into account, maximum output current
Switching Frequency
system variable switching frequency system (the switching frequency varies with input voltage output load), there some degree freedom switching frequency selection. However, frequency must least 25kHz minimize audible noise. Higher switching frequencies will decrease transformer noise, will also increase level switching power dissipated power devices. minimum switching frequency maximum duty cycle full load expressed 50kHz where minimum input voltage 50kHz 0.5, respectively.
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Power Transformer Design Calculations
AN2228 APPLICATION NOTE
STD1LNK60Z MOSFET Turn Ratio
maximum MOSFET drain voltage must below breakdown voltage. maximum drain voltage
input voltage, secondary reflected voltage, voltage spike (caused primary parasitic inductance maximum input voltage).
maximum input voltage 375V STD1LNK60Z MOSFET breakdown voltage 600V. Assuming that voltage drop output diode 0.7V, voltage spike 95V, margin least 50V, reflected voltage given )DSS Turn Ratio given where, Secondary reflected voltage V(BR)DSS MOSFET breakdown voltage Vmargin Voltage margin VDC(max) Maximum input voltage Vspk Voltage spike Voltage drop Turn Ratio Primary Winding Turns Secondary Winding Turns
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AN2228 APPLICATION NOTE
Power Transformer Design Calculations
Primary Current
Primary Peak Current expressed 0.48 0.152A
Primary Root Mean Square (RMS) Current expressed prms 0.152 0.062A
where, Ippk Primary peak current Voltage output IO(max) Maximum current output
Efficiency, equal
Dmax Maximum duty cycle VDC(min) Minimum input voltage Iprms Primary current
Primary Inductance
Primary Inductance expressed 5.92mH 0.152 where, (min) Minimum Input voltage (min) Minimum switching frequency Dmax Maximum duty cycle fs(min) Minimum switching frequency Ippk Primary peak current example, Primary Inductance 5.2mH, minimum switching frequency 57kHz 0.152
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Power Transformer Design Calculations
AN2228 APPLICATION NOTE
Magnetic Core Size
most common ways choose core size based Area Product (AP), which product effective core (magnetic) cross-section area times window area available windings. Using EE16/8 core standard horizontal bobbin this particular application, equation used estimate minimum cm4) shown
1.316 prms
where, Primary Inductance Iprms Primary current Window utilization factor, equal margin wound construction, triple insulated wire construction
Bmax Saturation magnetic flux density
Temperature rise core
1.6.1
Primary Winding
Winding Turns
effective area EE16 core 20.1mm2 core's datasheet). number turns primary winding calculated 0.22 20.1 where, Primary Winding Turns (min) Minimum Input voltage Dmax Maximum duty cycle fs(min) Minimum switching frequency
Flux density swing
Effective area core
8/26
AN2228 APPLICATION NOTE
Power Transformer Design Calculations
1.6.2
Wire Diameter
current density (AJ) allowed flow through chosen wire 4A/mm2. Copper diameter primary wire expressed where, Diameter primary winding wire Iprms Primary current Current density prms 0.062 0.142mm
1.6.3
Number Primary Winding Turns Layer
EE16 bobbin window about 9mm, enamel wiring chosen 0.21mm outer diameter 0.17mm Copper diameter, number turns layer expressed 0.21 where, Layer Primary Winding Turns turns layer, layers needed (total turns layers)
1.6.4
Practical Flux Swing
Using value, practical flux swing expressed 0.234T 20.1 where,
Flux density swing
VDC(min) Minimum input voltage Dmax Maximum duty cycle fs(min) Minimum switching frequency Effective area core Primary Winding Turns
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Power Transformer Design Calculations
AN2228 APPLICATION NOTE
Secondary Winding
Using triple insulation wire with 0.21mm Copper diameter, number turns secondary winding expressed where, Secondary Winding Turns (total turns primary winding layers) Primary Winding Turns Number turns primary winding layer
1.8.1
Auxiliary Winding
Winding Turns
MOSFET gate voltage minimum input voltage should conduct MOSFET completely. this application, optocoupler powered fly-back method, number auxiliary winding turns auxiliary winding calculated where, Gate voltage VDC(min) Minimum input voltage Auxiliary Winding Turns Primary Winding Turns Optocoupler voltage Fly-back voltage Secondary Winding Turns
10/26
AN2228 APPLICATION NOTE
Power Transformer Design Calculations
1.8.2
Wire Diameter
With auxiliary winding turns =11), enamel wire chosen 0.21mm outer diameter 0.17mm Copper diameter. Copper diameter primary wire expressed
Length
length setting based number primary winding turns primary inductance during manufacturing process. Note: practice, saturation current value must ensured. not, then design activity should restarted.
11/26
STD1LNK60Z-based Control Circuit Components
AN2228 APPLICATION NOTE
STD1LNK60Z-based Control Circuit Components
MOSFET
STD1LNK60Z (see Appendix STD1LNK60Z-based Circuit Schematics page built-in, back-to-back Zener diodes specifically designed enhance only Electrostatic Discharge (ESD) protection capability, also allow possible voltage transients (that occasionally applied from gate source) safely absorbed.
2.2.1
Startup Resistor
Minimum Power Dissipation
startup resistor limited power dissipation because high input voltage that moves across times. However, lower value faster startup speed power dissipation should less than converter's maximum output power. minimum power dissipation value expressed
1percent
0.01 0.01 0.48
2.2.2
Maximum Power Dissipation
4.2M, power dissipation expressed
0.0335W
2.2.3
Startup Resistors Power Margin
power rating resistor with footprint 0805 0.125W. Three resistors (1.2M, 1.2M, 1.8M, respectively) placed series produce required startup resistor value still have enough power margin.
12/26
AN2228 APPLICATION NOTE
STD1LNK60Z-based Control Circuit Components
Optocoupler Power Methods
There methods powering optocoupler:
fly-back (see Figure forward (see Figure
fly-back method chosen application because provides more stable power optocoupler. Figure Optocoupler Fly-back Power
STD1LNK60Z
R11a
3904
AI11829
Figure
Optocoupler Forward Power
STD1LNK60Z
R11a 3904
AI11830
13/26
STD1LNK60Z-based Control Circuit Components
AN2228 APPLICATION NOTE
2.4.1
Sense Resistor
Minimum Power Dissipation
Sense resistor used detect primary peak current. limited maximum power dissipation, which 0.1% maximum power. minimum power dissipation expressed 0.01 0.01 0.48 0.062 prms
2.4.2
Maximum Power Dissipation
3.4, maximum power dissipation expressed prms 0.062 0.013W
2.4.3
Sense Resistors Power Margin
resistors (6.8, 6.8, respectively) placed parallel produce required sense resistor value still have enough power margin. Ramp-up voltage (via Ippk), when added voltage [(I1+Ie)(R7+R achieves good output voltage current regulation (see Figure Note: value should much greater than value. minimum primary current, Ippk, maximum current, stead state minimum load, while maximum Ippk minimum stead state maximum load. cathode current, TL431 limited 1mA< <100mA, maximum diode current optocoupler PC817 50mA. order decrease quiescent power dissipation, maximum operation diode current, PC817 10mA. Current Transfer Ratio (CTR) PC817 about stead state. result, maximum operation transistor current PC817 also 10mA. Initially effect neglected. minimum load, maximum load, where, VQbe voltage; when voltage between base emitter transistor reaches this value, MOSFET turned off. purposes this application design: 360, 2.2nF; role accelerate MOSFET's turning OFF.
14/26
AN2228 APPLICATION NOTE
Figure Current Sense Circuit
Ippk
STD1LNK60Z-based Control Circuit Components
R11a
3904
AI11831
Constant Power Control
pole capacitor filter leading edge current spike avoid switch malfunction. However, will also lead delays primary peak transfer well turning result, different power inputs produced different input voltages. R11, R11a provide constant current, which proportional input voltage. This way, power inputs basically same different input voltages. Note: They must carefully selected adjusted achieve basically constant power input different input voltages. basic selection process expressed where, Current change Input voltage Primary Inductance Transfer delay relation present application, where, Auxiliary Winding Turns Primary Winding Turns Optocoupler voltage Fly-back voltage Secondary Winding Turns Zener diode voltage
15/26
STD1LNK60Z-based Control Circuit Components
AN2228 APPLICATION NOTE
Note: R11>> this case, only used: Note: Constant control accuracy good used, applying very simple. purposes this application design: 4.7nF,
Zero Current Sense
blocks current during starting allow charge delivered from input voltage through starting resistor until MOSFET turns first time. MOSFET input capacitor Ciss form voltage divider MOSFET gate, value should times more than that Ciss. This decreases MOSFET (full) turn-on delay. this case, 6.8nF. limits power dissipation zener diode inside MOSFET. selection process expressed
where, VDC(max) Maximum input voltage Auxiliary Winding Turns Primary Winding Turns Optocoupler voltage Fly-back voltage Secondary Winding Turns Zener diode voltage Zener diode current Note: external zener diode used maximum current zener diode 10mA, value 1.5K limits current PC817, value
16/26
AN2228 APPLICATION NOTE
STD1LNK60Z-based Control Circuit Components
Constant Voltage Constant Current
Constant Voltage (CV) configuration comprised error amplifier TL431, R21, R22, C11. TL431 provides reference voltage. divide output voltage compare with reference. compensates error amplifier TL431. limits optocoupler diode current (see Figure Figure page operation characteristics). purposes this application, devices selected are: R21=1k; R22=1k; C11=100nF; R19=150.
Constant Current (CC) established simply with transistor, R16, R18, R15, C10. Output current flows through sense resistor R16. turned when voltage drop reaches same value base turn-on voltage This increases current through optocoupler converter goes into constant current regulation. senses output current, limits base current rating power must then considered. 0.4A 0.5V, then
1.25
resistors, 2.2, with SMD1206 footprint placed parallel required power dissipation resistance value. Similarly, limits optocoupler's diode current constant current regulation. compensates constant current control. purposes this application, devices are: 360, 1nF. Note: parameters remaining transformer devices seen Bill Materials (BOM, Appendix STD1LNK60Z-based Circuit Bill Materials).
17/26
STD1LNK60Z-based Control Circuit Components
AN2228 APPLICATION NOTE
Figure
Curve 110VAC
AI11825
Note:
Figure
200V/div; time 4µs/div)
Curve 220VAC
AI11826
Note:
200V/div; time 4µs/div)
18/26
AN2228 APPLICATION NOTE
Test Results
Table
Test Results
Line Load Regulation
Load 4.749V 4.750V 4.750V 4.750V Full Load 4.743V 4.743V 4.743V 4.743V Load Regulation 85VAC 110VAC 220VAC 265VAC
Supply Voltage
±0.06% ±0.06% ±0.06% ±0.06%
Line Regulation
±0.01%
±0.0%
Note:
Table
Figure Figure page operation waveforms.
Efficiency Ratings
85VAC 2.754 4.743 69.0 110VAC 2.706 4.743 70.2 220VAC 2.918 4.743 65.1 265VAC 3.006 4.743 63.2 Units
Description Input power Output voltage Output current Output power Efficiency
Table
Input current Input power
Standby Power
100V 0.512A 51mW 160V 0.224A 36mW 300VDC 0.222A 67mW 375VDC 0.242A 91mW
Input voltage
19/26
Test Results
AN2228 APPLICATION NOTE
Figure
Drain Source Voltage Operation Waveform, 85VAC
Note:
Figure
100V/div; time 4µs/div
Drain Source Voltage Operation Waveform, 110VAC
Note:
100V/div; time 4µs/div
20/26
AN2228 APPLICATION NOTE
Figure Drain Source Voltage Operation Waveform, 220VAC
Test Results
Note:
200V/div; time 4µs/div)
Figure Drain Source Voltage Operation Waveform, 265VAC
Note:
200V/div; time 4µs/div)
21/26
Appendix STD1LNK60Z-based Circuit Schematics
AN2228 APPLICATION NOTE
Appendix STD1LNK60Z-based Circuit Schematics
Figure Control Circuit Components Schematic (see Section page
1N5819
TL431
3904
STD1LNK60Z
R11a
3904
AI11827
Figure STD1LNK60Z-based Schematic (full view)
1N4007 222/1KV STTH108 1N5819 330µ/16V 102/60V 3904 3904 102/Y2
P817
10/1W 1N4007
1N4007 150K/1W 4.7µF/400V 4.7µF.400V 1N4007
47µ/16V
0.1u/60V
TL431
STD1LNK60-1
1N4148
100µ/16V
AI11828
22/26
AN2228 APPLICATION NOTE
Appendix STD1LNK60Z-based Circuit Bill Materials
Appendix STD1LNK60Z-based Circuit Bill Materials
Table
Designator
Part Type 4.7uF/400V 4.7uF/400V 222/1KV 100u/16V 682/60V 222/60V 472/60V 330u/16V 47u/16V 102/60V 0.1u/60V 102/Y2 10/1W 150K/1W 1.8M 1.2M 1.2M 1.5K 1/2W 0805A 0805A 0805A 0805A 0805A 0805A 0805A 0805A 0805A 0805A 0805A 0805A 0805A 1206R 1206R 0805 0805A 0805A 0805A 0805A 0805A Foot Print Inductor Electric Capacitor Electric Capacitor Ceramic Capacitor Electric Capacitor Capacitor Capacitor Capacitor Electric Capacitor Electric Capacitor Capacitor Capacitor Capacitor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor 105°C 105°C 105°C 85°C 85°C Description Accurate
23/26
Appendix STD1LNK60Z-based Circuit Bill Materials
AN2228 APPLICATION NOTE
Designator
Part Type 1N4007 1N4007 1N4007 1N4007 STTH108 1N4148 1N5819 Jumper
Foot Print 0805 0805 0805 0805 DO-41 DO-41 DO-41 DO-41 DO-41
Description Resistor Resistor Resistor Resistor Diode Diode Diode Diode Diode Diode
Accurate
DO-41
Diode Jumper MOSFET Bipolar Bipolar Optocoupler
STD1LNK60 IPAK MMBT3904 MMBT3904 P817 TL431 SOT23L SOT23L DIP4 TO92L
Sharp
24/26
AN2228 APPLICATION NOTE
Revision History
Revision History
Date 22-August-2005 Revision First edition Changes
25/26
Revision History
AN2228 APPLICATION NOTE
Information furnished believed accurate reliable. However, STMicroelectronics assumes responsibility consequences such information infringement patents other rights third parties which result from use. license granted implication otherwise under patent patent rights STMicroelectronics. Specifications mentioned this publication subject change without notice. This publication supersedes replaces information previously supplied. STMicroelectronics products authorized critical components life support devices systems without express written approval STMicroelectronics. logo registered trademark STMicroelectronics. other names property their respective owners 2005 STMicroelectronics rights reserved STMicroelectronics group companies Australia Belgium Brazil Canada China Czech Republic Finland France Germany Hong Kong India Israel Italy Japan Malaysia Malta Morocco Singapore Spain Sweden Switzerland United Kingdom United States America www.st.com
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