BYD BF1560 For 5V1.5A手机充电器方案

BF1560 For 5V1.5A Charger Design

Table of Contents BF1560 for High Efficiency Charger Design: (AC Input 90-264Vac,Output 5V 1.5A, No-Load Standby Power <30mW, Meet “Europe COC Tier 2”Efficiency)
1. Introduction……………………………………………………….......................................2 2. Design Features…………………………………………..................................................3 3. Power Supply Design Specification………………………………………………….4 4. Schematic……………………………………………………………………………………....5 5. PCB Layout………………………………………………………………………………….....6 6. Bill of Materials………………………………………………….......................................7 7. Transformer Drawing………………………………………...………………………......8 8. Efficiency……………………………………………………..…….......................................9 9. CV and CC Regulation………….…………………………...........................................10 10. Output Ripple Voltage………………………………………………………………….11 11. Turn-on Delay Time ……………..……………………………………………………..12 12. Output Rise Time….……………………………………………………………………..13 13. Dynamic Load Response ……………………………………………………………..14 14. MoU………………………..…………………………………………………………………..15 15. Common Mode Noise …………………………………………………………………….16 16. Vce Waveform………………………………………..………………………………….17 17. Thermal Test…………………………..…………………………………………………... 18 18. Conducted EMI …….………………………………………………………………………19 19. Radiated EMI …………………………………………………………………………........20
-1-

1. Introduction
This document provides a reference design for a universal AC input, 5V 1.5A isolated fly-back adapter. For this design the BF1560 is used. It contains the complete specification of the power supply, a detailed circuit diagram and PCB layout, the entire bill of materials required to build the power supply, drawing of the power transformer, and test data of the most important performance.
Figure 1 Circuit Board Photograph
-2-

2. Design Features
?AC input range 90-264Vac ? DC output 5V 1.5A ? Meet “30mW” no-load standby power consumption requirement ?Meet “Europe COC Tier 2” Efficiency requirement at end of USB ?Max Ripple Voltage < 80mV ?Meet “USB3.0” Dynamic Load Response Requirement
-3-

3. Power Supply Design Specification
Description Input Voltage Line Frequency Standby Power Output Voltage Output Current Output Voltage Output Current Ripple&Noise Continuous Output Power Over Current Protection Active Mode Efficiency Symbol Vin F / Vout_cv Iout_cv Vout_cc Iout_cc Vripple Pout Iout_max η Min 90 47 / 4.75 0 2 1.5 / / / 76.6 Type Input Section / 264 50/60 63 / 30 Output Characteristics 5 / / / / 7.5 / / Time sequence Turn-on delay time Hold up time Conducted/Radiation EMI Safety ESD Ambient Temperature / / / 10 / 2 / / Environmental Meets CISPR22B/EN55022B Meets IEC950,UL1950,Class Ⅱ / /
-4-
Max
Units Vac Hz mW V A V A mV W A %
Comment / / 230Vac Measured at end of USB / / / Measured at end of USB 20MHz Bandwidth / Auto-restart Measured at end of USB Vin=115Vac&230Vac Full load Full load / / / Free convection,sea level
CV CC
5.25 1.7 4.75 1.7 80 / 1.7 /
S mS
/ TAMB
15 -5
/ 45
KV ℃

4. Schematic
Figure 2 Design Schematic
-5-

5. PCB Layout
PCB Top
PCB Bottom
Figure 3 PCB Layout 28.3 mm x 36.6 mm
-6-

6. Bill of Materials
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Designator C1 C2 C3 C4 C5 C6 C7 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 BD1 D2 D3 D4 D5 IC1 L1 L2 FR1 T1 Q1 CY1 Total Description E-Capacitor 6.8uF/400V 8*12 105℃ ±20% E-Capacitor 8.2uF/400V 8*14 105℃ ±20% SMD Capacitor 0805 470pF/250V 105℃ ±20% X7R E-Capacitor 1.0uF/50V 5*10 105℃ ±20% SMD Capacitor 0603 47nF/50V 105℃ ±20% X7R E-Capacitor 680uF/6.3V 6*12 105℃ ±20% Solid-Capacitor 470uF/6.3V 6*8 105℃ ±20% SMD Resistor 1206 5.1M ±5% SMD Resistor 0805 200K ±5% SMD Resistor 0805 270R ±5% SMD Resistor 0603 51R ±5% SMD Resistor 0603 16K ±1% SMD Resistor 0603 3.9K ±1% SMD Resistor 0603 5.6K ±1% SMD Resistor 0603 4.7K ±1% SMD Resistor 1206 3R ±1% SMD Resistor 0805 3.6R ±1% SMD Resistor 0805 6.2K ±5% TB10S 1A/1000V M7 1A 1000V SMA FAST DIODE RS1M 1A/1000V SMA SMD Schottky Diode SS34L 3A/40V SMB PWM Controller IC BF1560 SOT-23-6 Fixed inductor 220uH 4*10 SMD Ferrite Bead 0805 1.5K @100MHz Fusible Resistor 5.1R/1W 5% Transformer EE16 Lp=1.45mH 13005 TO-126 HFE>25 BVcbo>700V Y-CAP 100pF/250V Qty 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 32
-7-

7. Transformer Drawing
-8-

8. Efficiency
Measure at end of USB Vin (Vac) Pin (W) Iout (mA) Vout (V) Pout(W) 0.012 2.43 115V/ 60Hz 4.9 7.42 10.03 0.025 2.48 230V/ 50Hz 4.9 7.38 9.94 0 375 750 1125 1500 0 375 750 1125 1500 5.01 5.05 5.11 5.17 5.23 4.99 5.05 5.11 5.17 5.23 0 1.89 3.83 5.82 7.85 0 1.89 3.83 5.82 7.85 η(%) / 77.93 78.21 78.38 78.21 / 76.21 78.16 78.86 78.97 78.05 51 78.18 47 AVG η(%) F (KHz)
Level V Efficiency(%) :71.2(0.075*LnPo+0.561) Europe COC Tier 2 Efficiency(%) :76.6(0.0834*LnPo-0.0014*Po+0.609)
-9-

9.CV and CC Regulation
VI Curve (Vin=115Vac/60Hz)
5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
VOUT (V) VOUT (V)
IOUT (A) VI Curve (Vin=230Vac/50Hz)
5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
IOUT (A)
-10-

10. Output Ripple Voltage
Vin=115V Full Load △V=63.2mV
Vin=230V Full Load △V=63.2mV
-11-

11. Turn-on Delay Time
Vin=90V, Full Load △T=1250mS
Vin=264V, Full Load △T=374mS
-12-

12. Output Rise Time
Vin=90V, Full Load △T=4.68mS
Vin=264V, Full Load △T=4.56mS
-13-

13. Dynamic Load Response
Test Conditions: 1. Load: 0.15A-1.35A-0.15A; 2. Frequency: 100Hz;
3. Duty-Cycle: 50%; 4. Slew-Rate: 0.1A/us
Vin=90V Vo_max=5.17V Vo_min=4.89V
Vin=264V Vo_max=5.16V Vo_min=4.89V
-14-

14. MoU
Test Conditions: 1. Vin=230Vac/50Hz; 2. Load: 10R Resistive Load; 3. The Length of Output DC-Cable: 1M;
EPS Switching Frequency Component V_pp=1.20V
-15-

15. Common Mode Noise
Test Conditions: 1. Vin=230Vac/50Hz; 2. Load: 10R Resistive Load; 3. The Length of Output DC-Cable: 1M;
V_pp= -60.5dB
-16-

16. Vce Waveform
Test Condition: Vin=264Vac, Iout=1.5A
Result: Vce_max=620V
Appendix-Simple Specification for used transistor (D13005E ,TO-126)
Parameter Collector-Base Voltage Collector-Emitter Voltage Emitter- Base Voltage Collector Current Power Dissipation Ta=25℃ Tc=25℃ Symbol Vcbo Vceo Vebo Ic Ptot Tj Tstg Rating 800 450 9 4 2 75 150 -55~150 Unit V V V A W ℃ ℃
Junction Temperature Storage Temperature -17-

17. Thermal Test
Note: The UUT is assembled with case and placed in a temperature chamber. Item IC1(BF1560) BJT(Q1,D13005E) Transistor Core(T1, EE16) Transformer Wire(T1,EE16) Schottky Diode(D4 D5,SS54) Ambient Temperature Iout=1.5A Vin=90Vac T(℃) Tr(℃) 97.1 52.1 99.1 54.1 90.1 45.1 101.6 56.6 100.0 55.0 45℃
-18-

18. Conducted EMI
Vin=230Vac/50Hz, Neutral Amplitude(dBuV)
Frequency(MHz) Vin=230Vac/50Hz, Live Amplitude(dBuV)
Frequency(MHz)
-19-