TNY266P_1

Design Example Report Title 4.9W power supply using TNY266P Input: 90 – 265 VAC Specification Output: 5V/1.5A, 3.3V/1.5A, 12V/0.5A, -12V/15mA Application Author Document Number Date Revision DVD Player Power Integrations Applications Department DER-10 February 4, 2004 1.0 Summary and Features • • • • • • • Low cost no common-mode choke no Y-cap no X-cap low EMI even with output grounded good output cross-regulation even with no TL431 ~ 200 mW input power during standby using low-cost “DC Switch” 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. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-10 4.9W DVD power supply using TNY266P February 4, 2004 Table Of Contents Introduction................................................................................................................. 3 Photograph................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic................................................................................................................... 6 Circuit Description ...................................................................................................... 7 5.1 Input EMI Filtering ............................................................................................... 7 5.2 Primary Clamp Snubber ...................................................................................... 7 5.3 Output filtering..................................................................................................... 7 5.4 Output Feedback................................................................................................. 7 5.5 “DC Switch” ......................................................................................................... 7 6 PCB Layout ................................................................................................................ 8 7 Bill Of Materials .......................................................................................................... 9 8 Transformer Specification......................................................................................... 10 8.1 Electrical Diagram ............................................................................................. 10 8.2 Electrical Specifications..................................................................................... 10 8.3 Materials............................................................................................................ 10 8.4 Transformer Build Diagram ............................................................................... 11 8.5 Copper Foil Preparation .................................................................................... 11 8.6 Transformer Construction.................................................................................. 12 9 Transformer Spreadsheets....................................................................................... 13 10 Performance Data................................................................................................. 16 10.1 Standby Input Power during DC switch off operation ........................................ 16 10.2 Full-load Efficiency ............................................................................................ 16 10.3 Input Power Consumption during Standby ........................................................ 16 10.4 Cross Regulation............................................................................................... 17 Thermal Performance............................................................................................... 17 11 Minimum Operating Voltage and Peak Power Margin .......................................... 17 12 Output ripple and Noise Waveforms ..................................................................... 18 13 Conducted EMI ..................................................................................................... 20 14 Revision History.................................................................................................... 21 Important Notes: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built. 1 2 3 4 5 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 1 Introduction This document is an engineering report describing an 4.9W (8.5 W peak) multiple output power supply utilizing a TNY266P for a DVD player. This design is low cost and meets EMI with no common-mode choke, no X-cap, and no Y-cap. This is possible with TinySwitch-II because of its built-in frequency jitter. Cross-regulation is tight in spite of having a simple low-cost zener regulation scheme. This is possible with TinySwitch-II because of its unique feedback scheme. A low-cost non-Safety rated “DC Switch” allows shutdown with ~200 mW consumption at 230 Vac. This is possible with TinySwitch-II because of its EcoSmart features. This document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. Page 3 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-10 4.9W DVD power supply using TNY266P February 4, 2004 2 Photograph Note the following: • Does not use common-mode choke, X-cap, nor Y-cap • Uses little board space • Does not use a heatsink • Uses small transformer: EE25L • Uses small output capacitors • Uses small output diodes • Does not use TL431 Figure 1 – Power Integrations PSU unit Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 3 Power Supply Specification Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Output Voltage 3 Output Ripple Voltage 3 Output Current 3 Output Voltage 4 Output Ripple Voltage 4 Output Current 4 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Ambient Temperature TAMB Meets CISPR22B / EN55022B Symbol VIN fLINE Min 90 47 Typ Max 265 64 0.3 Units VAC Hz W V mV A V mV A V mV A V mV A Comment 2 Wire – no P.E. 50/60 VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 3.6 1 5.0 1 12 0.2 -12 0.012 100 0.013 100 0.5 50 1.5 50 1.5 20 MHz Bandwidth ± 5% 20 MHz Bandwidth 20 MHz Bandwidth zener regulated 20 MHz Bandwidth POUT POUT_PEAK η 4.9 8.5 71 W W % Measured at full load, 25 oC 0 40 o C Free convection, sea level Page 5 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-10 4.9W DVD power supply using TNY266P February 4, 2004 4 Schematic Figure 2 – Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 5 Circuit Description 5.1 Input EMI Filtering C1, and C2 are the bulk capacitors. Together with L1, they form the EMI filter. TinySwitch-II’s built-in frequency jitter helps achieve low EMI in spite of this very simple EMI filter. 5.2 Primary Clamp Snubber D5, R1, R2, and C3 form the primary clamp snubber to clamp the voltage spike at the Drain pin after turn-off. D5 is a 1N4007G, a glass-passivated version of the standard 1N4007, with controlled reverse recovery. Its use, along with R2, improves EMI and efficiency. 5.3 Output filtering C6, C8, and C12 are the main output capacitors. C7, C9, and C11, along with L3, L4, and L5, form second-stage output filters. 5.4 Output Feedback U2, VR1, and R15 form the voltage feedback network. The 5V output voltage setpoint is set by the voltage drops of U2, VR1, and R15. The TinySwitch-II unique feedback scheme, with constant feedback current over line and load changes, means that the current in the zener does not change, thus the voltage drops in U2, VR1, and R15 do not change. This yields tight regulation in spite of the circuit’s simplicity and low cost. 5.5 “DC Switch” J4 is connected to a switch, wherein if it is closed, the 5V output drops to about 1.2V, because the zener ZR1 is essentially shorted out. All the output drop to about 1/5th of their normal voltages. During this condition, the load draws very little current. Because of the TinySwitch’s EcoSmart operation, it draws very little input power - 0.6 (Increase VOR, Larger input capacitor, Larger TinySwitch Core Type Core Bobbin AE LE AL BW M L NS DC INPUT VOLTAGE PARAMETERS ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES eel25 EEL25 P/N: PC40EE25.4/32/6.4-Z EEL25_BOBBIN P/N: * 0.404 cm^2 Core Effective Cross Sectional Area 7.34 cm Core Effective Path Length 1420 nH/T^2 Ungapped Core Effective Inductance 22.3 mm Bobbin Physical Winding Width 3 mm Safety Margin Width (Half the Primary to Secondary Creepage Distance) 1 Number of Primary Layers 4 Number of Secondary Turns Page 13 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-10 VMIN VMAX 4.9W DVD power supply using TNY266P 89 375 Volts Volts February 4, 2004 Minimum DC Input Voltage Maximum DC Input Voltage CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.57 IAVG 0.13 IP 0.33 IR 0.19 IRMS 0.18 TRANSFORMER PRIMARY DESIGN PARAMETERS LP 1909 NP 80 ALG 298 2215 BM BAC 573 ur LG BWE OD INS DIA AWG CM CMA 2053 0.13 16.3 0.20 0.04 0.16 35 32 180 Amps Amps Amps Amps Maximum Duty Cycle Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current uHenries Primary Inductance Primary Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Gauss Flux Density, IP (BP 0.1 mm) mm Effective Bobbin Width mm Maximum Primary Wire Diameter including insulation mm Estimated Total Insulation Thickness (= 2 * film thickness) mm Bare conductor diameter AWG Primary Wire Gauge (Rounded to next smaller standard AWG value) Cmils Bare conductor effective area in circular mils Cmils/A !!!!!!!!!! INCREASE CMA>200 (increase mp L(primary layers),decrease NS,larger Core) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 6.50 Amps Peak Secondary Current ISRMS 3.06 Amps Secondary RMS Current IO 1.71 Amps Power Supply Output Current IRIPPLE 2.54 Amps Output Capacitor RMS Ripple Current CMS 613 Cmils Secondary Bare Conductor minimum circular mils AWGS 22 AWG Secondary Wire Gauge (Rounded up to next larger standard AWG value) DIAS 0.65 mm Secondary Minimum Bare Conductor Diameter ODS 4.08 mm Secondary Maximum Outside Diameter for Triple Insulated Wire INSS 1.71 mm Maximum Secondary Insulation Wall Thickness VOLTAGE STRESS PARAMETERS VDRAIN PIVS 626 24 Volts Volts Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 CMS1 AWGS1 DIAS1 ODS1 3.6 0.600 2.16 0.5 2.98 1.075 0.89 18 215 26 0.41 5.47 Volts Amps Watts Volts Amps Amps Volts Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Cmils Output Winding Bare Conductor minimum circular mils AWG Wire Gauge (Rounded up to next larger standard AWG value) mm Minimum Bare Conductor Diameter mm Maximum Outside Diameter for Triple Insulated Wire 2nd output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 CMS2 AWGS2 DIAS2 ODS2 12.0 0.100 1.20 0.7 9.24 0.179 0.15 55 36 34 0.16 1.76 Volts Amps Watts Volts Amps Amps Volts Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Cmils Output Winding Bare Conductor minimum circular mils AWG Wire Gauge (Rounded up to next larger standard AWG value) mm Minimum Bare Conductor Diameter mm Maximum Outside Diameter for Triple Insulated Wire 3rd output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 CMS3 AWGS3 DIAS3 ODS3 23.0 0.100 2.30 0.7 17.24 0.179 0.15 104 36 34 0.16 0.95 Volts Amps Watts Volts Amps Amps Volts Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage Cmils Output Winding Bare Conductor minimum circular mils AWG Wire Gauge (Rounded up to next larger standard AWG value) mm Minimum Bare Conductor Diameter mm Maximum Outside Diameter for Triple Insulated Wire Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 15 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 10 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 10.1 Standby Input Power during DC switch off operation Note that less than 200mW “DC Switch” power consumption is possible with TinySwitchII because of its EcoSmart features. Standby Consumption 200 Input Power (mW) 160 120 80 40 0 85 115 145 175 205 235 265 Input Voltage (VAC) Figure 7- Standby Input Power vs. Input Line Voltage 10.2 Full-load Efficiency Efficiency at 115 Vac, with continuous load drawn by DVD player during playback. PI unit: 71% 10.3 Input Power Consumption during Standby “Standby” is achieved by turning off the unit using the remote control, with no DVD in the tray. PI unit: 4.8W Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 10.4 Cross Regulation Minimum and Maximum output voltages were recorded for each output, while cycling the unit on/off, start/stop, pause/run, chapter jump, and fast forward/rewind. The test was done at room temperature, 90 Vac, 115 VAC 132 Vac, 180 Vac, 230 Vac, 265 Vac input. Note the tight regulation of the PI 3.6V output in spite of the low-cost, simple Zener regulation. This is possible with TinySwitch-II because of its unique feedback scheme. Output 3.6 V 5V +12 V -12 V Minimum 3.644 4.96 11.68 -12.48 Maximum 3.848 5.04 12.56 -12.40 Tolerance +6.89 / +1.22% +0.80 / -0.80% +4.67 / -2.67% +4.00 / -3.33% Thermal Performance Note: The Power Supply was installed in the DVD player enclosure. The DVD player was playing a DVD. Temperature rise is less than 25 °C Temperature (°C) Item Ambient (Deg.C) Transformer (T1) TNY266 (U1) Rectifier (D8) 90 VAC 25 35 48 38 265VAC 25 38 53 51 11 Minimum Operating Voltage and Peak Power Margin The unit is capable of starting and running as low as 60 Vac in spite of the small total input capacitance of 32uf. This indicates plenty of margin for the DVD player’s peak power requirements, as flyback power supplies deliver less maximum power when the AC input voltage is low. Page 17 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-10 4.9W DVD power supply using TNY266P February 4, 2004 12 Output ripple and Noise Waveforms The ripple and noise were measured during normal DVD operation and switches between different functions at room temperature, 90 VAC input. Note the low output ripple and noise in spite of small output capacitors. The TinySwitch-II shows fast transient response because of its unique feedback scheme. Figure 8 – 3.6V, 1s, 50 mV/div Figure 9 – 5V, 1s, 50 mV/div Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 Figure 10 – 12V, 1s, 500 mV/div Figure 11 – -12V, 1s, 50 mV/div Page 19 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-10 4.9W DVD power supply using TNY266P February 4, 2004 13 Conducted EMI EMI was tested at room temperature, during normal operation, playing a DVD. Note the lower EMI, especially with output grounded, in spite of having no common mode choke, no Y-cap and no X-cap. The excellent EMI is possible with TinySwitch-II because of its built-in frequency jitter. Note that in normal use, the DVD player is connected to the TV, and the TV chassis is grounded through the antenna wire or cable. Therefore the EMI setup that is representative of the actual application is with the output grounded back to the LISN ground plug. Figure 12 – 230V, Line (worst case), floating output. Figure 13 – 230V, Line (worst case), output grounded. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 22 DER-10 4.9W DVD power supply using TNY266P February 4, 2004 14 Revision History Date February 4, 2004 Author DZ/JC Revision 1.0 Description & changes First Release Reviewed AM/VC Page 21 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-10 4.9W DVD power supply using TNY266P February 4, 2004 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 and DPA-Switch are trademarks of Power Integrations, Inc. © Copyright 2003, Power Integrations, Inc. WORLD HEADQUARTERS NORTH AMERICA - WEST Power Integrations 5245 Hellyer Avenue San Jose, CA 95138 USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: usasales@powerint.com CHINA Power Integrations International Holdings, Inc. Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu Shenzhen Guangdong, 518031 Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 EUROPE & AFRICA Power Integrations (Europe) Ltd. Centennial Court Easthampstead Road Bracknell Berkshire RG12 1YQ, United Kingdom Phone: +44-1344-462-300 Fax: +44-1344-311-732 e-mail: eurosales@powerint.com KOREA Power Integrations International Holdings, Inc. Rm# 402, Handuk Building, 649-4 Yeoksam-Dong, Kangnam-Gu, Seoul, Korea Phone: +82-2-568-7520 Fax: +82-2-568-7474 e-mail: koreasales@powerint.com SINGAPORE Power Integrations, Singapore 51 Goldhill Plaza #16-05 Republic of Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com TAIWAN Power Integrations International Holdings, Inc. 17F-3, No. 510 Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore, India 560052 Phone: +91-80-226-6023 Fax: +91-80-228-9727 e-mail: indiasales@powerint.com APPLICATIONS FAX World Wide +1-408-414-9760 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 22