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power integrations 5245 hellyer avenue, san jose, ca 95138 usa. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com design example report title 9w power supply using tny267p specification input: 85 ? 265 vac output: 5v/0.75a, 3.3v/0.5a, 12v/100ma, -12v/10 ma, -23v/10 ma, floating 3v/100 ma application dvd player author power integrations applications department document number der-7 date february 4, 2004 revision 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 .
der-7 9w dvd power supply using tny267p february 4, 2004 page 2 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com table of contents 1 introduction................................................................................................................. 3 2 photograph................................................................................................................. 4 3 power supply specification ........................................................................................ 5 4 schematic................................................................................................................... 6 5 circuit descr iption ...................................................................................................... 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 mate rials .......................................................................................................... 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.
der-7 9w dvd power supply using tny267p february 4, 2004 page 3 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 pow er supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
der-7 9w dvd power supply using tny267p february 4, 2004 page 4 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 figure 1 ? power integrations psu unit ac input dc output dc switch
der-7 9w dvd power supply using tny267p february 4, 2004 page 5 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 3 power supply specification description symbol min typ max units comment input voltage v in 85 265 vac 2 wire ? no p.e. frequency f line 47 50/60 64 hz no-load input power (230 vac) 0.3 w output output voltage 1 v out1 3.3 v output ripple voltage 1 v ripple1 33 mv 20 mhz bandwidth output current 1 i out1 0.5 1.5 a output voltage 2 v out2 5.0 v 5% output ripple voltage 2 v ripple2 50 mv 20 mhz bandwidth output current 2 i out2 0.75 1.5 a output voltage 3 v out3 12 v output ripple voltage 3 v ripple3 60 mv 20 mhz bandwidth output current 3 i out3 0.1 0.5 a output voltage 4 v out4 -12 v zener regulated output ripple voltage 4 v ripple4 60 mv 20 mhz bandwidth output current 4 i out4 0.01 a output voltage 5 v out5 -23 v output ripple voltage 5 v ripple5 400 mv 20 mhz bandwidth output current 5 i out5 0.01 .08 a output voltage 6 v out6 3.0 v floating output for display output ripple voltage 6 v ripple6 200 mv 20 mhz bandwidth output current 6 i out6 0.1 a total output power continuous output power p out 9.0 w peak output power p out_peak 10.5 w efficiency 72 % measured at full load, 25 o c environmental conducted emi meets cispr22b / en55022b ambient temperature t amb 0 40 o c free convection, sea level
der-7 9w dvd power supply using tny267p february 4, 2004 page 6 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 4 schematic figure 2 ? schematic.
der-7 9w dvd power supply using tny267p february 4, 2004 page 7 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 trans former 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 1/5 th 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.
der-7 9w dvd power supply using tny267p february 4, 2004 page 8 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7 bill of materials item qty reference description p/n manufacturer 1 2 c1, c4 22 f, 400 v kmg400vb22m nippon chemi-con 2 1 c2 1.0 nf, 1 kv, ceramic z5u dielectric any 3 2 c6, c9 82 f, 35 v kmg35vb82m nippon chemi-con 4 1 c10 10 f, 50 v kmg50vb10m nippon chemi-con 5 2 c17, c18 470 f, 10 v, low esr ky10vb470mk30 nippon chemi-con 6 2 c11 c12 1000 f, 10 v, 60 m ? ky10vb1000mj16 nippon chemi-con 7 1 c19 0.1 f, 50 v, ceramic z5u dielectric any 8 2 c15, c20 100 f, 25 v, low esr kze25vb100mj16 nippon chemi-com 9 1 c21 100 f, 10 v low esr kmg10vb100m nippon chemi-con 10 1 c22 0.01 f, 50 v ceramic any 11 c23 1000 pf, 100v ceramic any 12 4 d1, d2, d3, d4 1 a, 600 v 1n4007 any 13 1 d5 1 a, 600 v, glass passivated 1n4007gp vishay / any 14 1 d7 uf4003 any 15 2 d9, d12 1n4148 any 16 1 d8 bav20 any 17 2 d10, d11 1n5822 any 18 1 f1 3.15 a, 250 vac any 19 1 l1 1.5 mh 0.25 a sbc3-152-251 tokin, or equiv. 10 1 l3, l4 3.3 h, 2.66 a 822ly-3r3m toko, or equiv. 21 2 l2, l5 ferrite bead any 22 2 r5, r14 100 ? , 1/4 w, 5% any 23 1 r6 39 k ? , 1/4 w, 5% any 24 1 r4 200 k ? , 1/2 w, 5% any 25 1 r13 10 k ? , 1/4 w, 5% any 26 1 r12 1.0 k ? , 1/2w 5% any 27 1 r15 10 ? , 1/4w, 5% any 28 1 z1 12v, 1/2 w, 5% 1n4742 any 29 1 z2 4.7v, 1/4 w, 2% bzx79-b4v7 any 30 1 z3 5.6v, 1/2 w, 5% 1n4734a any 31 1 t1 eel25 custom any 32 1 u1 tinyswitch-ii tny267p power integrations 33 1 u2b, u2a pc817a isocom / any 34 1 pcb any 35 1 sw1 dc switch any
der-7 9w dvd power supply using tny267p february 4, 2004 page 9 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8 transformer specification 8.1 electrical diagram 60t x 2 1 4 14 1t x 3 11 13 12t 12 2t x 3 4t 8 primary nc 5 shield copper 7 6 14t x 3 bias +12 v +5 v +3.3 v -23 v w2 w3 w1 w6 w5 w4 w7 9 2t 10 f+/- w8 figure 4 ?transformer electrical diagram 8.2 electrical specifications electrical strength 1 second, 60 hz, from pins 1-7 to pins 8-14 3000 vac primary inductance pins 1-4, all other windings open. measured at 132 khz, 1 vrms 1.43 mh +/- 10% resonant frequency pin 1-4, all other windings open 300 khz (min.) primary leakage inductance pins 1-4, with pins 8-14 shorted. measured at 132 khz, 1 vrms 20 h (max.)
der-7 9w dvd power supply using tny267p february 4, 2004 page 10 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.3 materials item description [1] core: eel25, tdk gapped for al of 392 nh/t 2 [2] bobbin: eel25 vertical 14 pins [3] magnet wire: # 32 awg [4] magnet wire: #28 awg [5] magnet wire: #26 awg [6] copper foil 0.12 mm thick, 16 mm wide. [7] tape: 3m 1298 polyester film, 16.1 mm wide [8] tape: 3m 1298 polyester film, 22.1 mm wide [9] margin tape: 3m # 44 polyester web. 3.0 mm wide [10] teflon [11] copper tape 2.0 mils thick, 16 mm wide. [12] varnish 8.4 transformer build diagram f-/f+ +12 v - 23 v 13 5 10 11 14 primary shield 5 v 12 7 6 bias 3.3v 13 1 4 12 8 11 9 figure 5 ? transformer build diagram.
der-7 9w dvd power supply using tny267p february 4, 2004 page 11 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.5 copper foil preparation 0.12 mm thick. pin 5 45 mm +5 v out 1t copper foil 16 mm wide. #28 aw g figure 6 ? foil winding preparation diagram. 8.6 winding instructions bobbin set up orientation set up the bobbin with its pin1 to pin7 oriented to the left hand side. margin tape apply 3.0 mm margin at each side of bobbin using item [9]. match combined height of primary, shield and bias windings. w1 bias winding 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. basic insulation apply 2 layers of tape item [7] w2 two layers primary winding 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. basic insulation apply 2 layers of tape item [7] w3 copper shield 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. basic insulation apply 3 layers of tape item [8] margin tape apply 3.0 mm margin at each side of bobbin using item [9]. match combines height of secondary windings. w4 3.3 v winding. 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. w5 +5v winding 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. basic insulation apply one layer of tape item [7] w6 +12 winding 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. basic insulation apply one layer of tape item [7] w7 -23 v winding 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. w8 f- / f+ winding 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. outer insulation 3 layers of tape [8] for insulation. core assembly assemble and secure core halves. item [1] final varnish dip varnish uniformly in item [12]
der-7 9w dvd power supply using tny267p february 4, 2004 page 12 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9 performance data all measurements performed at room temperature, 60 hz input frequency. 9.1 standby input power dur ing dc switch operation standby consumption 0 50 100 150 200 250 300 85 115 145 175 205 235 265 input voltage (vac) input power (mw) figure 7 - standby input power vs. input line voltage
der-7 9w dvd power supply using tny267p february 4, 2004 page 13 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 minimum maximum 3.3 v 3.288 v 3.468 v 5 v 5.08 v 5.24 v +12 v 12.28 v 13.4v -12 v -11.68 v -11.76 v -23 v -21.88 v -24,08 v f- / f+ 2.24 v 2.744 v 10 thermal performance temperature of top267 during normal operation, case of dvd player closed. temperature rise is less than 30 o c. item 85 vac 265 vac ambient 25 c 25 c tinyswitch ( 267p) 45.4 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.
der-7 9w dvd power supply using tny267p february 4, 2004 page 14 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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
der-7 9w dvd power supply using tny267p february 4, 2004 page 15 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com measured results figure 10: +12 v, 5 ms, 20 mv /div figure 11: -12 v, 5 ms, 200 mv /div
der-7 9w dvd power supply using tny267p february 4, 2004 page 16 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com measured results figure 12: -23 v, 5 ms, 200 mv /div figure 13: f- / f+, 5 ms, 200 mv /div
der-7 9w dvd power supply using tny267p february 4, 2004 page 17 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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
der-7 9w dvd power supply using tny267p february 4, 2004 page 18 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com figure 16 ? line, output grounded figure 17 ? neutral, output grounded
der-7 9w dvd power supply using tny267p february 4, 2004 page 19 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 14 revision history date author revision description & changes reviewed february 4, 2004 yg 1.0 first release am/vc
der-7 9w dvd power supply using tny267p february 4, 2004 page 20 of 20 power integrations tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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 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 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 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 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 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 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 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 hotline world wide +1-408-414-9660 applications fax world wide +1-408-414-9760

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