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| Design Example Report Title Generic PCB for DVD Player using TinySwitch-II 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-9 February 4, 2004 1.0 Summary and Features * * * * * * * * * * Multiple Output PCB using TinySwitch-II Suitable for multiple output DVD supplies Suitable for many different output configurations Uses 14-pin EEL25 core Low EMI even with output grounded 3 tested circuits shown: TNY264, TNY266, and TNY267 Low cost no common-mode choke, no Y-cap, no X-cap 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-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 Table Of Contents 1 2 3 4 Introduction................................................................................................................. 3 Generic Power Supply PCB Layout............................................................................ 4 Schematic................................................................................................................... 5 Circuit Description ...................................................................................................... 6 4.1 Input EMI Filtering ............................................................................................... 6 4.2 Primary Clamp Snubber ...................................................................................... 6 4.3 Output filtering..................................................................................................... 6 4.4 Output Feedback................................................................................................. 6 4.5 "DC Switch" ......................................................................................................... 6 4.6 +8V Option .......................................................................................................... 6 4.7 -22V option ......................................................................................................... 6 4.8 Floating +3V and Its Bias Option......................................................................... 7 4.9 -12V Linear Regulator Option............................................................................. 7 Bill Of Materials - Generic PSU with all options ......................................................... 8 Example One - 5.7W TNY264 DVD PSU .................................................................. 9 6.1 DVD Power Requirements .................................................................................. 9 6.2 Schematic ......................................................................................................... 10 6.3 Bill Of Materials ................................................................................................. 11 6.4 Transformer Electrical Diagram......................................................................... 12 The Original 5.7W design in ASM-140292 used an EE19 core. Error! Bookmark not defined. 6.5 Cross Regulation............................................................................................... 12 6.6 Design Option with EEL25 - Spreadsheet ......................................................... 12 Example Two - 8.5W TNY266 DVD PSU ................................................................ 15 7.1 Specification...................................................................................................... 15 7.2 Schematic ......................................................................................................... 16 7.3 Bill of Materials.................................................................................................. 17 7.4 Transformer Electrical Diagram......................................................................... 18 7.5 Cross Regulation............................................................................................... 18 Example Three - 11.6W TNY267 DVD PSU............................................................ 19 8.1 Specification...................................................................................................... 19 8.2 Schematic ......................................................................................................... 20 8.3 Bill of Materials.................................................................................................. 21 8.4 Transformer Electrical Diagram......................................................................... 22 8.5 Cross Regulation............................................................................................... 23 Revision History ....................................................................................................... 24 5 6 7 8 9 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. Page 2 of 25 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 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. Page 3 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 1 Introduction This document is an engineering report describing a generic multiple output power supply PCB layout utilizing TinySwitch-II for a wide range of application of DVD players. 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 4 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 2 Generic Power Supply PCB Layout Figure 1 - Printed Circuit Board Note: C17 and R14 are not stuffed, C23 and R17 are connected in series and attached to D9 (pin1 and pin2) on the bottom side Page 5 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 3 Schematic Figure 2 - Generic schematic showing all options Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 26 DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 4 Circuit Description 4.1 Input EMI Filtering C1 and C2 are the bulk capacitors. Together with L1 and L2, they form the EMI filter. TinySwitch-II's built-in frequency jitter helps achieve low EMI in spite of this very simple EMI filter. C18 is an option for a high voltage ceramic capacitor in case a single electrolytic capacitor is required for the bulk capacitor. 4.2 Primary Clamp Snubber D5, R1, R2, and C3 form the primary clamp snubber to clamp the voltage spike at the Drain pin after TinySwitch-II 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. 4.3 Output filtering C6, C8, C10, C12 and C14 are the main output capacitors. C7, C9, C11 and C13, along with L3, L4, L5 and R8, form second-stage output filters. 4.4 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. 4.5 "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 outputs drop to about 1/5th of their normal voltages. During this condition, the load draws very little current. Because of TinySwitch-II's EcoSmart operation, it draws very little input power - <200 mW. This "DC Swtich" can be used in place of a normal "AC Switch" that's used to disconnect the AC power. The DC Switch is lower cost because it does not have to be Safety-rated, and is lower voltage. 4.6 +8V Option Q1, R4, R5 and R6 form a linear regulator to generate +8V in case of +8V is required. VR3 is another solution of generating +8V. Yet another option is to use a zener as a series pass element. 4.7 -22V option R8 and C13 form a post-stage filter for -22V. Page 7 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 4.8 Floating +3V and Its Bias Option D11 and C14 rectify and filter the AC voltage to generate a floating +3V. R10 and R11 are the option if the floating voltage needs a reference voltage. The level of the reference voltage can be adjusted by assigning different resistance value to R10 and R11. 4.9 -12V Linear Regulator Option -12V is regulated through the coupling between -22V and 5V windings. Because its load usually is quite light, which is about tens of milliamps, the regulation should be enough for most applications. The option of a linear regulator U4 is provided if the tight regulation is preferred for the -12V. Page 8 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 5 Bill Of Materials - Generic PSU with all options 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 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Qty 1 1 1 1 2 2 1 1 1 2 1 1 1 2 1 4 1 3 1 2 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 Reference C1* C2* C3 C18 C15, C19 C16, C23 C22 C12 C6 C8, C10 C9 C11 C4 C7, C14 C13 D1, D2, D3, D4 D5 D6, D10, D11 D7 D8, D9* Q1 F1 L1 L2, L3 L4, L5 R1 R2, R12 R3 R4 R5 R6 R8 R9 R10 R11 R13 R15 R16, R17 VR1 VR2 VR3 T1 U1 U2 U4 J4 J1 J2, J3 PCB Description P/N Manufacturer Nippon Chemi-Con Nippon Chemi-Con Any Any Any Any Any Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Any Vishay / Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Power Integrations Isocom / Any National Semi Any Any Any 22 F, 400 V KMG400VB22RM 22 F, 400 V KMG400VB22RM 2.2 nF, 1 kV, ceramic Z5U dielectric 0.1 F, 630V, polyester 0.1 F, 100 V, ceramic Z5U dielectric 470 pF, 100 V, ceramic Z5U dielectric 680 pF, 100 V, ceramic Z5U dielectric 82 F, 35 V KMG35VB82RM 100 F, 25 V, low esr KZE25VB101M 470 F, 10 V, low esr KZE10VB471M 330 F, 10 V, low esr KZE10VB331M 220 F, 10 V, low esr KZE10VB221M 47 F, 50 V, low esr KZE50VB47RM 47 F, 25 V, low esr KZE25VB47RM 10 F, 50 V, low esr KZE50VB10RM 1 A, 1000 V, Glass Passivated 1N4007GP 1 A, 1000 V, Glass Passivated 1N4007GP BAV20 UF4003, 200V IN5822 2N4401, Transistor, 0.5A, 40V 1A/275V Fuse 1.5 mH, 0.25 A Ferrite Bead 3.3 H, 1 A 200 K, 1/2 W, 5% 200 , 1/4 W, 5% 30 k, 1/4 W, 5% 10 k, 1/4 W, 5% 1.6 k, 1/4 W, 5% 9.1 k, 1/4 W, 5% 1 , 1/4 W, 5% 680 , 1/2 W, 5% Customer Option Customer Option 16 , 1/4 W, 5% 910 , 1/4 W, 5% 6.8 , 1/4 W, 5% 4.3 V, 1/4 W, 2% BZX79-B4V3 12 V, 1/4 W, 2% BZX79-B12V 8.2 V, 1/4 W, 2% BZX79-B8V2 EEL25 Custom TinySwitch-II TNY266P Opto-coupler PC817A Linear Regulator LM13121Z-12, TO-92 DC Switch Custom AC Input Connector Custom DC Output Connector Custom Note: C1 and C2 could be changed to smaller capacitance according to actual output power, D9 should be changed to SB360 if the O/P is 3.6V. Page 9 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 6 Example One - 5.7W TNY264 DVD PSU A 5.7 W multiple output power supply was designed and successfully used to operate an Apex AD-1110 DVD player which was bought from a store. Performance using TNY264P exceeded the original power supply. The original design used a different, full-custom PCB. However, it could be implemented using this generic PCB. 6.1 DVD Power Requirements Description Input Voltage Frequency 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 VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 Min 90 47 Typ Max 265 64 Units VAC Hz V mV A V mV A V mV A V mV A Comment 2 Wire - no P.E. 50/60 3.3 0.44 5.0 0.54 12 0.017 -12 0.004 20 MHz Bandwidth 0.5 5% 20 MHz Bandwidth 0.74 20 MHz Bandwidth 20 MHz Bandwidth POUT POUT_PEAK 4.4 5.7 66 W W % Measured at full load, 25 oC 0 40 o C Free convection, sea level Note: Actual max current capability of PSU prototype is much higher than DVD player requirements Page 10 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 6.2 Schematic Figure 3 - Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 11 of 26 DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 6.3 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 31 Bill Of Materials Qty 1 1 1 1 1 2 2 2 2 1 4 1 1 2 2 1 1 3 2 1 2 1 1 1 1 1 1 1 1 1 1 Reference C1 C2 C3 C19 C4 C6, C12 C8, C10 C7, C13 C11, C9 C16 D1, D2, D3, D4 D5 D6 D7, D10 D8, D9 RF1 L1 L2, L3, L6 L4, L5 R1 R2, R12 R3 R13 VR1 T1 U1 U2 J4 J1 J2 PCB Description P/N Manufacturer Nippon Chemi-Con Nippon Chemi-Con Any Any Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Any Any Vishay / Any Any Any Any Any Any Any Any Any Any Any Any Any Any Power Integrations Isocom / Any Any Any Any 4.7 F, 400 V KMG400VB4R7M 10 F, 400 V KMG400VB10RM 2.2 nF, 1 kV, ceramic Z5U dielectric 0.1 F, 100 V, ceramic Z5U dielectric 10 F, 63 V KMG63VB10RM 100 F, 25 V, low esr KZE25VB101M 470 F, 10 V, low esr KZE10VB471M 47 F, 25 V, low esr KZE25VB47RM 100 F, 10 V, low esr KZE10VB101M 2.2 nF, 100 V ceramic 1 A, 1000 V 1N4007 1 A, 1000 V, Glass Passivated 1N4007GP IN4936, 400V UF4003, 200V IN5819, 40V 8.2 , 1 W, Fusible Resistor 330 H, 0.2 A Ferrite Bead 3.3 H, 1 A 100 K, 1/2 W, 5% 100 , 1/4 W, 5% 16 k, 1/4 W, 5% 16, 1/4 W, 5% 4.7V, 1/4 W, 2% BZX79-B4V7 EE19 Custom TinySwitch-II TNY264P Opto-coupler PC817A DC Switch Custom AC Input Connector Custom DC output connector Custom Page 12 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 6.4 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 Transformer Electrical Diagram 1 6 +12 V W2 Primary 3 107T #36 AWG 8T #29 T.I.W x 2 W6 10 +5 V W5 2T #29 T.I.W x 2 W1 Bias 4 8 +3.3 V W4 53T #36 AWG 5 1 4T #25 T.I.W x 2 9 -12 V 14T #28 T.I.W W7 7 W3 Shield 4T #28 AWG x 5 NC Figure 4 -Transformer Electrical Diagram 6.5 Cross Regulation The extremes of voltages were measured in the actual DVD player, while going through start/stop/pause/load/eject cycles. Output Minimum Maximum Tolerance 3.3 V 3.28 V 3.35 V +/- 1.06% 5V 5.20 V 5.12 V +/- 0.79% +12 V 12.56V 12.92V +/- 1.01% -12 V -13.32V -12.92 V +/- 1.52% 6.6 Design Option with EEL25 - Spreadsheet The power supply was designed using an EE19 core. It is a smaller and lower cost core than the EEL25 that this generic PCB layout uses. However, an EEL25 can also be used for the design. The design spreadsheet for an EEL25 is provided below. The turns ratio, Vor, Krp and output power remain the same. Note that the EMI windings have to be re-tuned since the core has changed. Page 13 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 ACDC_TNY-II_Rev1_1_032701 Copyright Power Integrations Inc. 2001 INPUT INFO OUTPU UNIT T Volts Volts Hertz Volts Watts ACDC_TNYII_Rev1_1_032701.xls: TinySwitch-II Continuous/Discontinuous Flyback Transformer Design Spreadsheet ENTER APPLICATION VARIABLES VACMIN 90 VACMAX 265 fL 50 VO 5.1 PO 5.7 n 0.67 Z 0.6 tC 3 CIN 14.7 Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor mSecon Bridge Rectifier Conduction Time Estimate ds uFarads Input Filter Capacitor ENTER TinySwitch-II VARIABLES TNY-II TNY264 Chosen Device ILIMITMIN ILIMITMAX fS fSmin fSmax VOR VDS VD KP TNY264 Power Out 0.233 0.267 132000 120000 144000 98 21 0.4 0.62 Univers 115 Doubled/230V al 6W 9W Amps Amps Hertz Hertz Hertz Volts Volts Volts TINYSwitch Minimum Current Limit TINYSwitch Maximum Current Limit TINYSwitch Switching Frequency TINYSwitch Minimum Switching Frequency (inc. jitter) TINYSwitch Maximum Switching Frequency (inc. jitter) Reflected Output Voltage TINYSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.6 PC40EE25.4/32/6.4-Z * Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns 90 Volts 375 Volts Minimum DC Input Voltage Maximum DC Input Voltage 0.59 0.09 0.23 0.14 0.13 Amps Amps Amps Amps Maximum Duty Cycle Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current TRANSFORMER PRIMARY DESIGN PARAMETERS LP 2656 uHenrie s NP 107 ALG 232 nH/T^2 1642 Gauss BM BAC 442 Gauss ur 2053 LG 0.18 mm BWE 44.6 mm Primary Inductance Primary Winding Number of Turns Gapped Core Effective Inductance Flux Density, IP (BP<3000) AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 26 DER-9 OD INS DIA AWG CM CMA Generic PCB for DVD Player using TinySwitch-II 0.42 0.06 0.36 28 mm mm mm AWG February 4, 2004 Comme nt Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) 161 Cmils Bare conductor effective area in circular mils 1265 Cmils/A CAN DECREASE CMA < 500 (decrease L(primary mp layers),increase NS,smaller Core) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 4.15 Amps Peak Secondary Current ISRMS 1.91 Amps Secondary RMS Current IO 1.12 Amps Power Supply Output Current IRIPPLE 1.54 Amps Output Capacitor RMS Ripple Current CMS 381 Cmils Secondary Bare Conductor minimum circular mils AWGS 24 AWG Secondary Wire Gauge (Rounded up to next larger standard AWG value) DIAS 0.51 mm Secondary Minimum Bare Conductor Diameter ODS 3.72 mm Secondary Maximum Outside Diameter for Triple Insulated Wire INSS 1.60 mm Maximum Secondary Insulation Wall Thickness VOLTAGE STRESS PARAMETERS VDRAIN Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) PIVS 26 Volts Output Rectifier Maximum Peak Inverse Voltage TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 3.3 Volts Output Voltage IO1 0.440 Amps Output DC Current PO1 1.45 Watts Output Power VD1 0.4 Volts Output Diode Forward Voltage Drop NS1 4.04 Output Winding Number of Turns ISRMS1 0.750 Amps Output Winding RMS Current IRIPPLE1 0.61 Amps Output Capacitor RMS Ripple Current PIVS1 17 Volts Output Rectifier Maximum Peak Inverse Voltage CMS1 150 Cmils Output Winding Bare Conductor minimum circular mils AWGS1 28 AWG Wire Gauge (Rounded up to next larger standard AWG value) DIAS1 0.32 mm Minimum Bare Conductor Diameter ODS1 5.52 mm Maximum Outside Diameter for Triple Insulated Wire 2nd output VO2 12.0 Volts Output Voltage IO2 0.020 Amps Output DC Current PO2 0.24 Watts Output Power VD2 0.8 Volts Output Diode Forward Voltage Drop NS2 13.96 Output Winding Number of Turns ISRMS2 0.034 Amps Output Winding RMS Current IRIPPLE2 0.03 Amps Output Capacitor RMS Ripple Current PIVS2 61 Volts Output Rectifier Maximum Peak Inverse Voltage CMS2 AWGS2 DIAS2 ODS2 7 Cmils 41 AWG 0.07 mm 1.60 mm Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire 601 Volts Page 15 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 7 Example Two - 8.5W TNY266 DVD PSU Using a TNY266 in place of TNY264 of Example 1 can provide 2.8W more power. It was tested in an Apex AD-1225 DVD player, which was bought from a store. The new design's performance using TNY266P exceeded the original power supply's. The original design used a different, full-custom PCB. However, it could be implemented using this generic PCB. 7.1 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 4.9 8.5 71 W W % Measured at full load, 25 oC 0 40 o C Free convection, sea level * Actual Apex AD-1225 DVD player max current requirements are much lower than PSU capability Page 16 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 7.2 Schematic Generic PCB for DVD Player using TinySwitch-II February 4, 2004 Figure 5 - Schematic. Page 17 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 7.3 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 31 32 33 34 35 36 37 38 39 Bill of Materials Qty 1 1 1 1 1 1 2 1 1 1 1 1 1 4 1 2 1 1 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Reference C1 C2 C3 C19 C12 C6 C8, C10 C9 C11 C4 C7 C16, C23 C22 D1, D2, D3, D4 D5 D6, D10 D7 D8 D9 F1 L1 L2, L3 L4, L5 R1 R2, R12 R3 R9 R13 R16, R17 R15 VR1 VR2 T1 U1 U2 J4 J1 J2 PCB Description P/N Manufacturer Nippon Chemi-Con Nippon Chemi-Con Any Any Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Any Any Any Vishay / Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Power Integrations Isocom / Any Any Any Any 10 F, 400 V KMG400VB10RM 22 F, 400 V KMG400VB22RM 2.2 nF, 1 kV, ceramic Z5U dielectric 0.1 F, 100 V, ceramic Z5U dielectric 82 F, 35 V KMG35VB82RM 100 F, 25 V, low esr KZE25VB101M 470 F, 10 V, low esr KZE10VB471M 330 F, 10 V, low esr KZE10VB331M 220 F, 10 V, low esr KZE10VB221M 47 F, 50 V, low esr KZE50VB47RM 47 F, 25 V, low esr KZE25VB47RM 470pF, 100 V, ceramic Z5U dielectric 680pF, 100 V, ceramic Z5U dielectric 1 A, 1000 V, Glass Passivated 1N4007GP 1 A, 1000 V, Glass Passivated 1N4007GP BAV20 UF4003, 200V IN5822 SB360 1A/275V Fuse 1.5 mH, 0.25 A Ferrite Bead 3.3 H, 1 A 200 K, 1/2 W, 5% 200 , 1/4 W, 5% 30 k, 1/4 W, 5% 680 , 1/2 W, 5% 16 , 1/4 W, 5% 6.8 , 1/4 W, 5% 910 , 1/4 W, 5% 4.3 V, 1/4 W, 2% BZX79-B4V3 12 V, 1/4 W, 2% BZX79-B12V EEL25 Custom TinySwitch-II TNY266P Opto-coupler PC817A DC Switch Custom AC Input Connector Custom DC Output Connector Custom Page 18 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 7.4 Transformer Electrical Diagram 1 14 W2 Primary 3 5T 80T 13 W6 +12 V W5 1T X 3 +5 V 11 NC W3 Shield 1 7 Copper 3T X 3 12 W4 +3.3 V W7 -23 V 10 W1 Bias 6 17T 20T x 2 Figure 6 -Transformer Electrical Diagram 7.5 Cross Regulation The extremes of voltages were measured in the actual DVD player, while going through start/stop/pause/load/eject cycles. Output Minimum Maximum Tolerance 3.6 V 3.644 3.848 +6.89 / +1.22% 5V 4.96 5.04 +0.80 / -0.80% +12 V 11.68 12.56 +4.67 / -2.67% -12 V -12.48 -12.40 +4.00 / -3.33% Page 19 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 8 Example Three - 11.6W TNY267 DVD PSU This 9W (11.6W peak) power supply will meet most low end DVD players' power requirements. This design was tested in a DVD player. The performance using TNY267P exceeded the original power supply. The original design used a different, full-custom PCB. However, it could be implemented using this generic PCB. 8.1 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 Output Voltage 5 Output Ripple Voltage 5 Output Current 5 Output Voltage 6 Output Ripple Voltage 6 Output Current 6 Total Output Power Continuous Output Power Peak Output Power Efficiency Environmental Conducted EMI Ambient Temperature TAMB Meets CISPR22B / EN55022B Symbol VIN fLINE Min 85 47 Typ Max 265 64 0.3 Units VAC Hz W V mV A V mV A V mV A V mV A V mV A V mV A W W % Comment 2 Wire - no P.E. 50/60 VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 VOUT5 VRIPPLE5 IOUT5 VOUT6 VRIPPLE6 IOUT6 POUT POUT_PEAK 3.3 0.5 5.0 0.75 12 0.1 -12 0.01 -23 0.01 3.0 0.1 9.0 11.6 72 400 .08 200 33 1.5 50 1.5 60 0.5 60 20 MHz Bandwidth 5% 20 MHz Bandwidth 20 MHz Bandwidth zener regulated 20 MHz Bandwidth 20 MHz Bandwidth floating output for display 20 MHz Bandwidth Measured at full load, 25 oC 0 40 o C Free convection, sea level * Actual DVD player max current requirements are much lower than PSU capability Page 20 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 8.2 Schematic Generic PCB for DVD Player using TinySwitch-II February 4, 2004 Figure 7 - Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 21 of 26 DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 8.3 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 31 32 33 34 35 36 37 38 Bill of Materials Qty 2 1 1 1 2 2 2 1 1 1 1 4 1 3 1 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 Reference C1, C2 C3 C19 C12 C6, C7 C8, C10 C9, C11 C14 C4 C13 C16 D1, D2, D3, D4 D5 D6, D10, D11 D7 D8, D9 F1 L1 L2, L3 L4, L5 R1 R2 R12 R3 R9 R13 R8 R10 VR1 VR2 VR3 T1 U1 U2 J4 J1 J2, J3 PCB Description P/N Manufacturer Nippon Chemi-Con Any Any Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Any Any Vishay / Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Power Integrations Isocom / Any Any Any Any 20 F, 400 V KMG400VB20RM 1 nF, 1 kV, ceramic Z5U dielectric 0.1 F, 100 V, ceramic Z5U dielectric 82 F, 35 V KMG35VB82RM 100 F, 25 V, low esr KZE25VB101M 1000 F, 10 V, low esr KZE10VB102M 470 F, 10 V, low esr KZE10VB331M 100 F, 10 V, low esr KZE10VB101M 47 F, 50 V, low esr KZE50VB47RM 10 F, 50 V KMG50VB10RM 1 nF, 100 V, ceramic Z5U dielectric 1 A, 1000 V, Glass Passivated 1N4007GP 1 A, 1000 V, Glass Passivated 1N4007GP BAV20 UF4003, 200V IN5822 1A/275V Fuse 1.5 mH, 0.25 A Ferrite Bead 3.3 H, 1 A 200 K, 1/2 W, 5% 100 , 1/4 W, 5% 200 , 1/4 W, 5% 39 k, 1/4 W, 5% 680 , 1/2 W, 5% 10 , 1/4 W, 5% 1 , 1/4 W, 5% 10 K, 1/4 W, 5% 4.7 V, 1/4 W, 2% BZX79-B4V7 12 V, 1/4 W, 2% BZX79-B12V 5.6 V, 1/2 W, 5% 1N4742 EEL25 Custom TinySwitch-II TNY267P Opto-coupler PC817A DC Switch Custom AC Input Connector Custom DC Output Connector Custom Page 22 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 8.4 Transformer Electrical Diagram 1 14 W2 Primary 3 4T 60T x 2 13 W6 +12 V W5 1T X 3 +5 V 11 NC W3 Shield 1 6 Copper 2T X 3 12 W4 +3.3 V W7 -23 V 10 9 W1 Bias 7 12T 14T x 3 2T 8 W8 F+/- Figure 8 -Transformer Electrical Diagram Page 23 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 8.5 Cross Regulation The extremes of voltages were measured in the actual DVD player, while going through start/stop/pause/load/eject cycles. Output Minimum Maximum 3.3 V 5V +12 V -12 V -23 V F- / F+ 3.288 V 5.08 V 12.28 V -11.68 V -21.88 V 2.24 V 3.468 V 5.24 V 13.4V -11.76 V -24.08 V 2.744 V Page 24 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II February 4, 2004 9 Revision History Date February 4, 2004 Author DZ/JC Revision 1.0 Description & changes Initial Release Reviewed AM/VC Page 25 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-9 Generic PCB for DVD Player using TinySwitch-II 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. (c) 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 Page 26 of 26 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com |
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