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Design Example Report
Title Specification Application Author Document Number Date Revision 11W Power Supply using TNY267P Input: 200 - 264 VAC Output: 3.3V/0.7A, 5V/1.6A, 12V/0.4A, -12V/0.1A DVD Player Power Integrations Applications Department
DER-5 February 4, 2004 1.0
Summary and Features
* * * * * * 11W continuous, 17W peak 4 outputs No Load input power < 40 mW Very low cost EMI filter to meet CISPR-22 Tight cross-regulation High efficiency (75% minimum)
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-5
11W DVD Power Supply
February 4, 2004
Table Of Contents
1 2 3 4 Introduction................................................................................................................. 4 Power Supply Specification. ....................................................................................... 4 Schematic................................................................................................................... 5 Circuit Description ...................................................................................................... 6 4.1 Input EMI filtering ................................................................................................ 6 4.2 TinySwitch-II primary........................................................................................... 6 4.3 Output rectification .............................................................................................. 6 4.4 Output Feedback................................................................................................. 6 Performance Data ...................................................................................................... 7 5.1 Efficiency............................................................................................................. 7 5.2 Load Regulation .................................................................................................. 7 5.3 No Load Input Power........................................................................................... 7 Conducted EMI........................................................................................................... 8 Transformer................................................................................................................ 9 7.1 Transformer Schematic ....................................................................................... 9 7.2 Electrical Specifications..................................................................................... 10 7.3 Materials............................................................................................................ 10 7.4 Transformer Construction.................................................................................. 11 7.5 Copper Foil Preparation. ................................................................................... 11 7.6 Winding Instructions .......................................................................................... 12 Bill Of Materials ........................................................................................................ 13 Revision History ....................................................................................................... 14
5
6 7
8 9
List of Figures
Figure 1 - Schematic......................................................................................................... 5 Figure 2 - Conducted EMI EN550022 Class B, Line, Secondary return floating............... 8 Figure 3 - Conducted EMI EN550022 Class B, Line, Secondary return connected to Artificial hand.............................................................................................................. 8 Figure 4 - Transformer Winding Diagram ......................................................................... 9 Figure 5 - Transformer Construction Diagram. ............................................................... 11 Figure 6 - Transformer Foil Construction Diagram.......................................................... 11
List of Tables
Table 1 - Power Supply Specifications ............................................................................. 4 Table 2 - Efficiency at 220 Vac input ................................................................................ 7 Table 3 - Load Regulation. Line frequency 60HZ, ambient temperature .......................... 7 Table 4 - No Load Input Power ......................................................................................... 7 Table 5 - Transformer Electrical Specifications............................................................... 10 Table 6 - Transformer Bill of Materials............................................................................ 10 Table 7 - Bill of Materials ................................................................................................ 13
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Page 2 of 16
DER-5
11W DVD Power Supply
February 4, 2004
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.
Page 3 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
1 Introduction
This document is an engineering report describing the design of an AC-DC power supply with 220 Vac input and 4 outputs. The design, rated for 11 watts (17 watts peak), is implemented using a TNY267 controller and an EEL25 core with Flyback topology. This document shows specifications, schematic, performance, transformer construction, and BOM of the power supply.
2 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 Safety Ambient Temperature TAMB 0 50
o
Symbol VIN fLINE
Min 198 47
Typ 220 50
Max 265 53 0.040 3.40 50 0.70 5.25 75 1.60 12.84 100 400 -12.84 100 100
Units VAC Hz W V mV A V mV A V mV A V mV A W W %
Comment
2 Wire - no P.E.
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 POUT POUT_PEAK
3.20 0.30 4.75 0.30 11.16 100 -11.16 30
3.30 0.60 5.00 1.20 12.00 200 -12.00 50 11
3% 20 MHz Bandwidth 5% 20 MHz Bandwidth 7% 20 MHz Bandwidth 7% 20 MHz Bandwidth
17.00 75
Measured at POUT (16.31W), 25 o C
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
C
Free convection, Sea level
Table 1 - Power Supply Specifications
Page 4 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
3 Schematic
Figure 1 - Schematic
Page 5 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
4 Circuit Description
4.1 Input EMI filtering
The voltage from the AC mains is converted into a DC voltage by the full bridge rectifier D1, D2, D3, and D4, and by the filters C1, and C4. Internal jitter of the TNY267P allows for simple EMI filtering. C3, C8, and L1 provide enough filtering for the supply to pass CISPR22B/EN55022B specifications for conducted emissions. The design does not need a common mode choke.
4.2
TinySwitch-II primary
The high end of T1 is connected to the high voltage DC bus. Pin 4, the lower end of the primary winding, is connected to the DRAIN pin of the TinySwitch-II. Every time the TinySwitch-II is turned ON, the primary winding of T1 conducts current and a magnetic field is built up in the core of the transformer. Every time the TinySwitch-II turns OFF, Flyback transformer T1 changes polarity. Output rectifiers D7, D8, D10, and D11, now in forward bias, conduct current and allow the energy stored in the core to be transferred to the secondary circuit. The auxiliary winding of T1 powers the internal circuitry of the TinySwitch-II. This external bias helps to reduce the internal power consumed by the TinySwitch-II. Therefore the supply has very low power consumption under no load and light load conditions.
4.3
Output rectification
The switching voltage waveforms at the secondary windings of T1 are rectifier by D7, D8, D10, and D11. After rectification, the waveforms are smoothed by capacitor, and inductor filters. This filtering produces output DC voltages with very low ripple.
4.4
Output Feedback
Sensing resistors R16 and R15 detect any variation in the amplitude of the 3.3V and 5V outputs. These changes, due to changes in the output load or input voltage, are sampled to the input pin of the TL431 shunt regulator. The shunt regulator compares these variations with its internal voltage reference and drives a feedback current trough U2B proportional to the to the variations detected by R16 and R15. Opto-coupler U2 closes the control loop of the supply by transferring the feedback current to the output of the EN/UV pin on the primary side of the circuit.
Page 6 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
5 Performance Data
All measurements are performed at room temperature, 60 Hz input frequency. 5.1 Efficiency VO(V) 5.06 3.25 12.30 12.40 IO (A) 1.20 0.60 0.205 0.052 PO (W) 6.07 1.95 2.52 0.64 11.18 14.20 78.73
PO(Total) (W) PIN (W) Efficiency (%)
Table 2 - Efficiency at 220 Vac input
5.2
Load Regulation VIN (Vac) 220 220 220 220 V O(3.3V) (V) 3.26 3.23 3.32 3.29 IO(3.3V) (A) 0.3 0.7 0.3 0.7 VO(5V) (V) 5.04 5.13 4.86 4.95 IO(5V) (A) 0.3 0.3 1.6 1.6 VO(12V) (V) 11.87 12.08 12.15 12.33 IO(12V) (A) 0.4 0.4 0.4 0.4 VO(-12V) (V) -11.66 -11.87 -11.95 -12.14 IO(-12V) (A) 0.1 0.1 0.1 0.1
Table 3 - Load Regulation. Line frequency 60HZ, ambient temperature
5.3
No Load Input Power VIN (Vac) 200 220 264 PIN (mW) 26 29 37
Table 4 - No Load Input Power
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DER-5
11W DVD Power Supply
February 4, 2004
6 Conducted EMI
Peak
Avg.
Figure 2 - Conducted EMI EN550022 Class B, Line, Secondary return floating PO = 11 W, 220 VAC, 60 Hz
Peak
Avg
Figure 3 - Conducted EMI EN550022 Class B, Line, Secondary return connected to Artificial hand PO = 11 W, 220 VAC, 60 Hz
Note: Quasi-peak readings will be about 6 dB lower than Peak readings, yielding at least 9 dB margin.
Page 8 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
7 Transformer
7.1 Transformer Schematic
NC W1,Shield Wndg, 32T,#32x2 5 1 W2,Primary, 64T,#32x4 4 6 W3,bias Wndg, 6T,#32x4 7 7 W4,Shield Wndg, 4T,#32x4 NC
8 W5,+12V wndg, 4T,#32x4 13 W7,5V wndg, 1T,Cu Foil 9 W6,3.3V wndg, 2T,Cu Foil 11,12 W4,-12V wndg, 7T,#32x4 14
Figure 4 - Transformer Winding Diagram
Page 9 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
7.2
Electrical Specifications
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 60Hz 1minute, from Pins 1-7 to Pins 8-14 Pin 1 to Pin 4, all other windings open Measured at 132KHz. Pin 1 to Pin 4, all other windings open Pin 1 to Pin 4, Pins 8-14 shorted 3000 V ac 1.42 mH 5 % 300 kHz (Min.) 30 H Max.
Table 5 - Transformer Electrical Specifications
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] Description Core: EEL25, TDK Gapped for AL of 344 nH/T Bobbin: EEL25 Vertical 14 pins Magnet Wire: # 32 AWG Copper Foil 0.052 mm thick, 14 mm wide. Tape: 3M 1298 Polyester Film, 16.1 mm wide Tape: 3M 1298 Polyester Film, 22.1 mm wide Tape: 3M # 44 Polyester web. 3.0 mm wide Tape: 3M 1298 Polyester Film, 10 mm wide Copper Tape 2.0 mils thick, 20mm wide. Varnish Table 6 - Transformer Bill of Materials
2
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DER-5
11W DVD Power Supply
February 4, 2004
7.4
Transformer Construction
Margin Tape 3mm, 4 places Pin side W8(P12) W8(P14) W7(P13) W6,W7(P9) W6(P11) W5(P8) W5(P13) W4(7) W4(NC) W3(P6) W3(P7) W2(P4) W2(P1) W1(NC) W1(P5)
Figure 5 - Transformer Construction Diagram.
7.5
Copper Foil Preparation.
The following figure shows the copper foil to be used for +3.3V and +5V outputs (W6 and W7)
Start Pin 11
#26 Copper Wire
105mm
Connect Pin 9
#26 Copper Wire
45mm
Finish Pin 13
+3.3 Vout 2T Copper Foil 14.0mm wide. 0.52mm Thick.
+5 Vout 1T Copper Foil 14.0 mm wide. 0.52mm Thick.
Figure 6 - Transformer Foil Construction Diagram.
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DER-5 7.6 Winding Instructions
Bobbin Set Up Orientation Margin Tape
11W DVD Power Supply
February 4, 2004
Set up the bobbin with its pins oriented to the right hand side. Apply 3.0 mm margin tape at each side of bobbin. Match combines height of primary, shield and bias windings. Start with a floating lead. Wind 32 turns with # 32 x 2 (bifilar) magnet wire from left to right. Wind tightly and uniformly across entire width of bobbin. Finish at pin 5. Cut the starting lead jut at the starting of the winding. Apply one layer of 16.1mm width tape. Start on pin 1. Wind 32 turns with # 32 x 2 (bifilar) magnet wire from right to left. Apply one layer of 16.1mm width tape. Continue the same wire on second layer. Wind 32 turns from left to right. The two layers should be wound tightly with the turns uniformly distributed across entire width of bobbin. Finish on pin 4. Apply one layer of 16.1mm width tape. Start on pin 7. Wind 6 turns with # 32 x 4 (quadfilar) magnet wire. Wind from right to left in a single layer. The wires should be tightly and uniformly wound. Finish on pin 6. Apply one layer of 16.1mm width tape. Start with a floating lead. Wind 4 turns with # 32 x 4 (quadfilar) magnet wire. Wind from right to left in a single layer. The wires should be tightly and uniformly wound. Finish on pin 7. Cut the starting lead jut at the starting of the winding. Apply 3 layers of 22.1 mm width tape. Apply 3.0 mm margin tape at each side of bobbin. Match combines height of secondary windings. Start on pin 13. Wind 4 turns with # 32 x 4 (quadfilar) magnet wire. Wind from right to left in a single tightly wound layer. Finish on pin 8. Apply one layer of 16.1mm width tape. Prepare W6 and W7 by mummy wrapping the copper foil (item 4) with 22.1 mm tape as shown in figure 26. Start at pin 11. Wind 2 turns. Connect the second lead to pin 9 and wind 1 turn. Connect the end lead to pin 13. Apply one layer of 16.1mm width tape. Start at pin 14. Wind 7 turns with # 32 x 4 (quadfilar) magnet wire. Wind from right to left in a uniform and tightly wound layer. Finish on pin 12. Apply 3 layers of 22.1 mm width tape. Assemble and secure core halves. Place outside short ring of item [9] with tight contact to winding surface. Wrap the core right over the flux band with three layers of 22.1mm tape Impregnate uniformly with varnish.
W1: Shield winding Basic Insulation
W2: Primary winding
Basic Insulation W3: Bias winding Basic Insulation
W4: Shield winding
Insulation Margin Tape W5: +12V winding Basic Insulation W6: + 3.3V and W7: + 5V windings Basic Insulation W7: -12 V winding Outer Insulation Core Assembly Belly band Outer Insulation Final Assembly
Page 12 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
8
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 31 32 33 34 35 36 37 Qty 2 1 1 2 2 1 1 1 2 1 2 1 5 2 1 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Reference C1, C4 C2 C3 C6, C9 C7, C10 C8 C11 C12 C14, C19 C15 C17, C18 C20 D1, D2, D3, D4, D5 D5 D8, D7 D9 D10, D11 F1 L1 L2 L3, L4 R1, R2 (Optional) R5 R6 R7 R8 R9 R10 R12 R13 R15 R16 T1 U1 U2 U3 VR1 Part Description. 10 F, 400V, Electrolytic 0.01F 1KV, Ceramic Disc 0.047F, 250VAC, X2 220 F, 25V, Electrolytic 10 F, 50V, Electrolytic 1nF, 250V, Y1 1000 F, 25V, Low ESR 1000 F, 10V, Low ESR 0.1F, 50V, Ceramic 470 F, 25V, Low ESR 470 F, 10V, Electrolytic 150 F, 25V, Electrolytic 1N4007, 1A, 1KV, Rectifier IN4007GP, 1000V, 1A UF4003, 1A, 200V, 1N4148, 75V, Rectifier. 1N5822, 3.0A, 40V, Schottky 3.15A, 250VAC 1.4mH, 0.5A 3.3 H, 1A, Inductor, 3.3 H, 2.7A, Inductor 1 M, 1/2W 47 , 1/4W 3.3 K, 1/8W 100 , 1/4W 1 K, 1/8W 200 , 1/8W 3.3 K, 1/8W 1 , 1/2W 10 K, 1%, 1/8W, 20 K, 1%, 1/8W 6.34 , 1%, 1/8W Transformer TNY267P PC817B, Optocoupler, CTR = 200 % TL431, Shunt Regulator P6KE180, TVS Zener, 180V, 600W.
Table 7 - Bill of Materials
Page 13 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
9 Revision History
Date February 4, 2004 Author MJ Revision 1.0 Description & changes Initial release Reviewed AM/VC
Page 14 of 16
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DER-5
11W DVD Power Supply
February 4, 2004
Notes
Page 15 of 16
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DER-5
11W DVD Power Supply
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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