Design Idea DI-12 TOPSwitch-GX 16 W, Universal

Input, Lead Acid Battery Charger

Application Battery Charger Device TOP244P Power Output 16 W Input Voltage 85-265 VAC Output Voltage 13.55 V at 25 C Topology Flyback

Design Highlights
Lowest cost and low component count solution Universal input voltage replaces the need for multiple linear based designs High efficiency: >75% Integrated line undervoltage detection (UV) and overvoltage (OV) power system surge protection Constant voltage / constant current (CV/CC) output Temperature compensated output voltage Monitor input to allow state of charge measurements

TOP244P requires no external heatsink, using the PC board instead. During the first 10 ms of operation, internal soft-start is enabled, lowering stresses on the internal power MOSFET, clamp and output rectifier. Built-in switching frequency jitter reduces conducted EMI, allowing the design to meet EN55022B limits with simple input filtering. Diode D1 and Zener VR1 clamp the leading edge drain voltage spike caused by transformer leakage inductance. Lead acid batteries for standby use are normally charged at ~2.3 V per cell and 0.1 A per Ah of capacity. Resistor R1, U2, C9, Q1, R3, R4 and R5 form the current limit circuit. Resistor R3 controls the current limit (1.2 A typical). Resistor R5 ensures sufficient voltage to drive the opto LED, even with the output shorted. Capacitor C9 and R4 provide compensation and limit Q1 base current. The output voltage is controlled using a TL431 voltage reference (U3). Resistors R7, R8, R9 and RT1 program output voltage as a function of temperature (Figure 3) to approximate that required by the lead-acid battery. During CV operation, DC gain is set by R6. Capacitor C8, C5 and R10 provide loop compensation. Bias for U3 is provided by R2.

Operation
The circuit shown in Figure 1 provides a CV/CC output for charging lead-acid batteries in applications such as fire/burglar alarms and emergency lighting. The design utilizes many of the features of the TOPSwitch-GX family. Line undervoltage and overvoltage (100 V and 450 V, respectively) are implemented using a single resistor (R13). Line undervoltage detection eliminates power-up/down output glitches, while overvoltage shutdown provides protection for short line transients and longer duration power system surges, removing the need for an input MOV. The DIP8 package of the

D1-D4 1N4007V 1 A, 1000 V

C7 1 nF Y1 VR1 P6KE 200 1 7,8

D2 UG4D 8T 24 AWG Triple Insulated 5,6 D3 BAV20

L2 3.3 H C2 560 F 35 V R2 1 k R1 4.7 C4 0.1 F 50 V U2 PC817A R8 52.7 k R6 470 C8 0.1 F Q2 2N4401 R7 11.8 k RT1 4.7 k C3 220 F 35 V

+13.55 V

D1 UF4005 L1 22 mH 2 C1 47 F 400 V U1 TOP244P

D M CONTROL C

R11 27 k

4 8T 30 AWG 3

R13 2 M

MON R12 10 k

TOPSwitch-GX

C6 0.1 F 250 VAC F1 3.15 A L

S

R10 6.8 C5 47 F 10 V Q1 2N4401 R3 0.5 1W

C9 0.47 F R4 470 R5 0.6 1W U3 TL431

85-265 VAC
N

R9 12.7 k RTN
PI-3404-112502

Figure 1. TOPSwitch Lead Acid Battery Charger.

DI-12

www.powerint.com

November 2002

DI-12
For battery detection and monitoring, R11, R12 and Q2 reduce the output voltage to approximately 8 V when a 5 V signal is applied to R12. This allows the battery voltage to be measured, giving the state of charge.
TRANSFORMER PARAMETERS
Core Material Bobbin TDK PC40 EE22/29/6-Z, 2 Gap for ALG = 145 nH/T YC 2204 (Ying Chin) Primary: 56T, 30 AWG Bias: 8T, 2 x 30 AWG Secondary: 8T, 28 AWG T.I.W. (T.I.W. = Triple Insulated Wire) Primary (2-1), tape, Bias (4-3), tape, Secondary (7,8-5,6) Primary: 475 H 10%, Leakage: 35 H (maximum) 300 kHz (minimum)

Key Design Points

The value of R3 sets the typical output current limit threshold given by: R3 = 0.6 / ILIMIT. Rate R3 and R5 accordingly for power dissipation (1 W). Ensure total voltage across R3 and R5 is greater than 1.5 V at ILIMIT if control to 0 V (output shorted) is required. Ensure voltage at cathode of D3 is >6 V at ILIMIT. Add additional bias winding turns, if necessary, to maintain output current control to 0 V (output shorted). RT1: Philips part # 2322-640-54472. Select tolerance of U2, R7, R8 and R9 to give the desired overall CV tolerance (R7, R8 and R9 as 0.1%; R10 as 1% and U2 as 0.5% gives overall tolerance <2%).
PI-2265-040401

Winding Details

Winding Order (Pin Numbers) Inductance Primary Resonant Frequency

Table 1. Transformer Construction Information.

2.45

2.40

16
Ambient Temperature = 30 C

Charging Voltage (V/cell)

2.35
Typical Limit

Output Voltage (V)

14

2.30

12

2.25

2.20

4
230 VAC 90 VAC
2.15 -10.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0

0 0 0.2 0.4 0.6 0.8 1.0 1.2

Temperature (C)

Output Current (A)

Figure 3. Cell Charging Voltage vs Temperature.

Figure 2. Output Characteristic (VOUT vs IOUT) For the latest updates, visit our Web site: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein, nor does it convey any license under its patent rights or the rights of others. The products and applications illustrated herein (including circuits external to the products and transformer construction) 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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch and EcoSmart are registered trademarks of Power Integrations, Inc. PI Expert is a trademark of Power Integrations, Inc. Copyright 2002, Power Integrations, Inc.
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A 11/02

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PI-2267-062598