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Design Example Report
Title 9W power supply using TNY267P Input: 85 - 265 VAC Specification Output: 5V/0.75A, 3.3V/0.5A, 12V/100mA, -12V/10 mA, -23V/10 mA, Floating 3V/100 mA Application Author Document Number Date Revision DVD Player Power Integrations Applications Department DER-7 February 4, 2004 1.0
Summary and Features * * * * * * Low cost no Y-cap no common-mode choke low EMI even with output grounded good output cross-regulation even with no TL431 ~ 200 mW input power with 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-7
9W DVD power supply using TNY267P
February 4, 2004
Table Of Contents
Introduction................................................................................................................. 3 Photograph................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic................................................................................................................... 6 Circuit Description ...................................................................................................... 7 5.1 Input Rectification................................................................................................ 7 5.2 Auxiliary Bias Supply........................................................................................... 7 5.3 Output Voltage Sensing, Feedback and DC switch............................................. 7 6 PCB Layout ................................................................................................................ 7 7 Bill Of Materials .......................................................................................................... 8 8 Transformer Specification........................................................................................... 9 8.1 Electrical Diagram ............................................................................................... 9 8.2 Electrical Specifications....................................................................................... 9 8.3 Materials............................................................................................................ 10 8.4 Transformer Build Diagram ............................................................................... 10 8.5 Copper Foil Preparation .................................................................................... 11 8.6 Winding Instructions .......................................................................................... 11 9 Performance Data .................................................................................................... 12 9.1 Standby Input Power during DC switch operation ............................................. 12 9.2 Cross Regulation............................................................................................... 13 10 Thermal Performance ........................................................................................... 13 11 Minimum Operating Voltage and peak power margin ........................................... 13 12 Output ripple and Noise Waveforms ..................................................................... 14 13 Conducted EMI ..................................................................................................... 17 14 Revision History.................................................................................................... 19 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
Page 2 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
1 Introduction
This document is an engineering report describing a 9W (10.5W peak) multiple output power supply utilizing a TNY267P 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 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
2 Photograph
Note the following: * Does not use common-mode choke, X-cap, nor Y-cap * Uses little board space * Uses small transformer: EE25L * Uses small output capacitors * Uses small output diodes * Does not use TL431 DC Output DC Switch AC Input
Figure 1 - Power Integrations PSU unit
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DER-7
9W DVD power supply using TNY267P
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 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 10.5 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
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DER-7
9W DVD power supply using TNY267P
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 20
DER-7
9W DVD power supply using TNY267P
February 4, 2004
5 Circuit Description
This circuit is configured as a flyback using the TNY267. 5.1 Input Rectification AC input power is rectified by a full bridge, consisting of D1 through D4. The rectified DC is then filtered by the bulk storage capacitors C1 and C2. Inductor L1, C1 and C2 form a pi () filter, which attenuates conducted differential-mode EMI noise. 5.2 Auxiliary Bias Supply The auxiliary bias supply circuit is made up of the primary-side transformer bias winding, diode D9, capacitor C10 and resistor R6. The bias voltage was given just enough current to disable the internal current source during "DC Switch" operation. In this case, the standby power consumption is minimized. 5.3 Output Voltage Sensing, Feedback and DC switch The combined voltage drops of Zener diode Z2 and optocoupler set the main output voltage. TinySwitch-II feedback current is independent of load allowing tight output voltage tolerance with this simple Zener circuit. The operation of the TinySwitch allows the use of a "DC switch" (SW1) to put the power supply in a standby condition, with very low consumption. The DC switch does not need to be safety-rated, and thus is much lower cost than an equivalent AC switch. During DC Switch operation, the 5C output is regulated at 1V, and all other outputs are at 1/5th of normal output voltage. The DVD system load is very low during this output voltage condition. The net result is that the input power is ~200 mW at 230 Vac input. This is possible with TinySwitch-II because of its EcoSmart features.
6 PCB Layout
Figure 3 Printed Circuit Layout.
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Page 7 of 20
DER-7
9W DVD power supply using TNY267P
February 4, 2004
7 Bill Of Materials
Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 10 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Qty
2 1 2 1 2 2 1 2 1 1 4 1 1 2 1 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1
Reference
C1, C4 C2 C6, C9 C10 C17, C18 C11 C12 C19 C15, C20 C21 C22 C23 D1, D2, D3, D4 D5 D7 D9, D12 D8 D10, D11 F1 L1 L3, L4 L2, L5 R5, R14 R6 R4 R13 R12 R15 Z1 Z2 Z3 T1 U1 U2B, U2A PCB SW1
Description
P/N
Manufacturer
Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Any Nippon Chemi-Com Nippon Chemi-Con Any Any Any Vishay / Any Any Any Any Any Any Tokin, or equiv. Toko, or equiv. Any Any Any Any Any Any Any Any Any Any Any Power Integrations Isocom / Any Any Any
22 F, 400 V KMG400VB22M 1.0 nF, 1 kV, ceramic Z5U dielectric Any 82 F, 35 V KMG35VB82M 10 F, 50 V KMG50VB10M 470 F, 10 V, low esr KY10VB470MK30 1000 F, 10 V, 60 m KY10VB1000MJ16 0.1 F, 50 V, ceramic Z5U dielectric 100 F, 25 V, low esr KZE25VB100MJ16 100 F, 10 V low esr KMG10VB100M 0.01 F, 50 V ceramic 1000 pF, 100V ceramic 1 A, 600 V 1N4007 1 A, 600 V, Glass Passivated 1N4007GP UF4003 1N4148 BAV20 1N5822 3.15 A, 250 VAC 1.5 mH 0.25 A SBC3-152-251 3.3 H, 2.66 A 822LY-3R3M Ferrite Bead 100 , 1/4 W, 5% 39 k, 1/4 W, 5% 200 K, 1/2 W, 5% 10 k, 1/4 W, 5% 1.0 k, 1/2W 5% 10 , 1/4W, 5% 12V, 1/2 W, 5% 1N4742 4.7V, 1/4 W, 2% BZX79-B4V7 5.6V, 1/2 W, 5% 1N4734A EEL25 Custom TinySwitch-II TNY267P PC817A DC switch
Page 8 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
8 Transformer Specification
8.1 Electrical Diagram
1 8
W2 Primary
4
4T 60T x 2
11
W6 +12 V
W5 1T X 3 +5 V
13
NC
W3 Shield
5 7
Copper 2T X 3
12
W4 +3.3 V W7 -23 V
14 10
W1 Bias
6
12T 14T x 3
2T
9
W8 F+/-
Figure 4 -Transformer Electrical Diagram
8.2
Electrical Specifications
1 second, 60 Hz, from pins 1-7 to pins 8-14 Pins 1-4, all other windings open. Measured at 132 kHz, 1 VRMS Pin 1-4, all other windings open Pins 1-4, with pins 8-14 shorted. Measured at 132 kHz, 1 VRMS 3000 VAC 1.43 mH +/- 10% 300 kHz (Min.) 20 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
Page 9 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
8.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] Description 2 Core: EEL25, TDK Gapped for AL of 392 nH/T Bobbin: EEL25 Vertical 14 pins Magnet Wire: # 32 AWG Magnet Wire: #28 AWG Magnet Wire: #26 AWG Copper Foil 0.12 mm thick, 16 mm wide. Tape: 3M 1298 Polyester Film, 16.1 mm wide Tape: 3M 1298 Polyester Film, 22.1 mm wide Margin tape: 3M # 44 Polyester web. 3.0 mm wide Teflon Copper Tape 2.0 mils thick, 16 mm wide. Varnish
8.4
Transformer Build Diagram
F-/F+
- 23 V +12 V 5V 3.3V
9 10 14 12 11 8 13 12 13 11
5 1 4 6 7
Shield
Primary
Bias
Figure 5 - Transformer Build Diagram.
Page 10 of 20
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DER-7 8.5
9W DVD power supply using TNY267P
February 4, 2004
Copper Foil Preparation
P in 5
#28 AW G
45 m m
+ 5 V O U T 1 T C o p p e r F o il 1 6 m m w id e . 0 .1 2 m m T h ic k .
Figure 6 - Foil Winding Preparation Diagram.
8.6
Winding Instructions
Set up the bobbin with its pin1 to pin7 oriented to the left hand side. Apply 3.0 mm margin at each side of bobbin using item [9]. Match combined height of primary, shield and bias windings. Start at pin 10 temporally. Wind 14 trifilar turns of item [4] from right to left. Wind tightly and uniformly across entire width of bobbin. Finish at pin 7 using item [10] at the finish leads. Flip the starting lead over to pin 6 using item [10] at the finish lead. Apply 2 layers of tape item [7] Start on pin 4 using item [10] at the start leads. Wind 30 bifilar turns of item [3] from left to right. Wind another 30 turns from right to left in second layer. Finish on pin 1 using item [10] at the finish leads. Apply 2 layers of tape item [7] Start on pin 5 using item [10] at the start leads. Wind 1 turns of copper shield shown in figure 6. Apply next step tape item[8] first before close this winding to avoid copper shortage. Apply 3 layers of tape item [8] Apply 3.0 mm margin at each side of bobbin using item [9]. Match combines height of secondary windings. Start at pin 13 using item [10] at the start leads. Wind 2 trifilar turns of item [5]. The wires should be tightly and uniformly wound spread across the bobbin width. Finish on pin 12 using item [4] at the finish leads. Start on pin 11 using item [10] at the start leads. Wind 1 trifilar turn of item [5]. Wind the wire between 3.3V windings. Finish on pin 13 using item [10] at the finish leads. Apply one layer of tape item [7] Start at pin 8 using item [10] at the start leads. Wind 4 turns of item [4]. Wind uniformly spread across the bobbin. Finish at pin 11 using item [10] at the finish leads. Apply one layer of tape item [7] Start at pin 12 using item [10] at the start leads. Wind 12 turns of item [4]. Wind from right to left in a uniform and tightly wound spread across the bobbin width. Finish on pin 14 using item [4] at the finish leads. Start at pin 10 using item [10] at the start leads. Wind 2 turns of item [4]. Finish at pin 9 using item [10] at the finish leads. 3 Layers of tape [8] for insulation. Assemble and secure core halves. Item [1] Dip varnish uniformly in item [12]
Bobbin Set Up Orientation Margin Tape
W1 Bias Winding Basic Insulation W2 Two Layers Primary Winding Basic Insulation W3 Copper Shield Basic Insulation Margin Tape W4 3.3 V Winding.
W5 +5V Winding Basic Insulation W6 +12 Winding Basic Insulation W7 -23 V Winding W8 F- / F+ Winding Outer Insulation Core Assembly Final Varnish
Page 11 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1 Standby Input Power during DC switch operation
Standby Consumption
300 Input Power (mW) 250 200 150 100 50 0 85 115 145 175 205 235 265 Input Voltage (VAC)
Figure 7- Standby Input Power vs. Input Line Voltage
Page 12 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
9.2 Cross Regulation Minimum and maximum output voltages were recorded, while cycling the unit on/off, start/stop, pause/run, chapter jump, and fast forward. The tests were done at room temperature, 115 VAC input. Note the tight regulation of the PI 3.3V output in spite of the low-cost, simple zener regulation. This is possible with TinySwitch-II because of its unique feedback scheme.
Output 3.3 V 5V +12 V -12 V -23 V F- / F+
Minimum 3.288 V 5.08 V 12.28 V -11.68 V -21.88 V 2.24 V
Maximum 3.468 V 5.24 V 13.4V -11.76 V -24,08 V 2.744 V
10 Thermal Performance
Temperature of TOP267 during normal operation, case of DVD player closed. Temperature rise is less than 30 oC.
Item Ambient TinySwitch (267P) 85 VAC 25 C 45.4 C 265 VAC 25 C 52.1 C
11 Minimum Operating Voltage and peak power margin
The unit is capable of starting and running as low as 68 VAC. 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 13 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
12 Output ripple and Noise Waveforms
The ripple and noise were measured during normal DVD operation 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. Measured Results
Figure 8: 3.3 V, 5 ms, 20 mV / div
Figure 9: 5 V, 5 ms, 20 mV / div
Page 14 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
Measured Results
Figure 10: +12 V, 5 ms, 20 mV /div
Figure 11: -12 V, 5 ms, 200 mV /div
Page 15 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
Measured Results
Figure 12: -23 V, 5 ms, 200 mV /div
Figure 13: F- / F+, 5 ms, 200 mV /div
Page 16 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
13 Conducted EMI
EMI was tested at room temperature, 230 VAC input, during normal operation. Note the very lower EMI (>12 dB margin), 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.
Figure 14 - Line, floating output
Figure 15 - Neutral, floating output
Page 17 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
Figure 16 - Line, output grounded
Figure 17 - Neutral, output grounded
Page 18 of 20
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DER-7
9W DVD power supply using TNY267P
February 4, 2004
14 Revision History
Date February 4, 2004 Author YG Revision 1.0 Description & changes First Release Reviewed AM/VC
Page 19 of 20
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DER-7
9W DVD power supply using TNY267P
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.
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