RDK-659 Power Integrations

Reference Design report for a 30 W Supply TM Title For Wall Outlet Using InnoSwitch3 -CP INN3268C-H202 180 VAC 265 VAC Input Specification 5.1 V, 6 A / 9.2 V, 3.3 A / 15.3 V, 2 A Output Application AC Outlet with USB Ports Author Applications Engineering Department Document RDR-659 Number Date July 16, 2020 Revision 1.2 Summary and Features 30W compact power supply for high power USB type A/C port charging. >89% average efficiency at nominal AC input <30 mW no-load input power All the benefits of secondary-side control with the simplicity of primary-side regulation Insensitive to transformer variation Extremely fast transient response independent of load timing Synchronous rectification for higher efficiency Accurate thermal protection with hysteretic shutdown Input voltage monitor with accurate brown-in/brown-out and overvoltage protection Meets IEC 2.0 kV common mode surge, 1.0 kV differential surge and EN55022 conducted EMI 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 <RDR-659 30 W USB Charger Using InnoSwitch3-CP 16-Jul-20 Table of Contents 1 Introduction ......................................................................................................... 5 2 Power Supply Specification ................................................................................... 7 3 Schematic ............................................................................................................ 8 4 Circuit Description ................................................................................................ 9 4.1 Input Circuit Description ................................................................................. 9 4.2 Primary-Side Circuit ....................................................................................... 9 4.3 Secondary-Side Circuit ................................................................................. 10 4.4 Design Key Points ........................................................................................ 11 5 PCB Layout ........................................................................................................ 13 6 Bill of Materials .................................................................................................. 14 7 Transformer (T1) Specification ............................................................................ 16 7.1 Electrical Diagram ........................................................................................ 16 7.2 Electrical Specifications ................................................................................ 16 7.3 Material List ................................................................................................ 16 7.4 Transformer Build Diagram .......................................................................... 17 7.5 Transformer Construction ............................................................................. 17 7.6 Winding Illustrations .................................................................................... 18 8 Common Mode Choke (L1) Specification .............................................................. 23 8.1 Electrical Diagram ........................................................................................ 23 8.2 Electrical Specifications ................................................................................ 23 8.3 Material List ................................................................................................ 23 8.4 Winding Instructions .................................................................................... 23 8.5 Illustrations ................................................................................................. 23 9 Transformer Design Spreadsheet ........................................................................ 24 10 Performance Data ........................................................................................... 27 10.1 Efficiency .................................................................................................... 27 10.1.1 Efficiency vs. Line ................................................................................. 27 10.1.2 Efficiency vs. Load ................................................................................ 28 10.1.3 No-Load Input Power ............................................................................ 29 10.2 Line and Load Regulation ............................................................................. 30 10.2.1 5.1 V Line Regulation at 6 A Load .......................................................... 30 10.2.2 9.2 V Line Regulation at 3.3 A Load ....................................................... 31 10.2.3 15.3 V Line Regulation at 2 A Load ........................................................ 32 10.2.4 5.1 V Load Regulation ........................................................................... 33 10.2.5 9.2 V Load Regulation ........................................................................... 34 10.2.6 15.3 V Load Regulation ......................................................................... 35 10.2.7 CV/CC vs. Line (5.1 V / 6 A) .................................................................. 36 10.2.8 CV/CC vs. Line (9.2 V / 3.3 A) ................................................................ 37 10.2.9 CV/CC vs. Line (15.3 V / 2 A) ................................................................. 38 11 Test Data ....................................................................................................... 39 11.1 Test Data Efficiency vs. Line, 5.1 V / 6 A (PCB End) ....................................... 39 11.2 Test Data Efficiency vs. Line, 9.2 V / 3.3 A (PCB End) .................................... 39 11.3 Test Data Efficiency vs. Line, 15.3 V / 2 A (PCB End) ..................................... 39 Power Integrations, Inc. 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