Design Example Report Title 9W power supply using TNY267P Input: 85 – 265 VAC Specification Output: 5V/0.56A, 3.3V/0.48A, 12V/100mA, -12V/15mA, -22V/100mA, Floating 4V/100mA Application DVD Player Author Power Integrations Applications Department Document Number DER-8 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 Low consumption during standby 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-8 9W DVD power supply using TNY267P February 4, 2004 Table Of Contents 1 2 3 Introduction................................................................................................................. 3 Photograph................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 4 Schematic................................................................................................................... 6 5 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 ................................................................................................................ 8 7 Bill Of Materials .......................................................................................................... 9 8 Transformer Specification......................................................................................... 11 8.1 Electrical Diagram ............................................................................................. 11 8.2 Electrical Specifications..................................................................................... 11 8.3 Materials............................................................................................................ 12 8.4 Transformer Build Diagram ............................................................................... 12 8.5 Copper Foil Preparation .................................................................................... 13 8.6 Winding Instructions .......................................................................................... 13 9 Performance Data .................................................................................................... 15 9.1 Efficiency........................................................................................................... 15 9.2 Standby Input Power at 2W load....................................................................... 16 9.3 Cross Regulation............................................................................................... 17 9.3.1 Play Mode .................................................................................................. 17 9.3.2 Stand-by Mode........................................................................................... 18 10 Conducted EMI ..................................................................................................... 19 11 Revision History.................................................................................................... 20 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 2 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 1 Introduction This document is an engineering report describing an 9W (11W peak) multiple output power supply utilizing a TNY267P for a DVD player supply. This design is low cost and meets EMI with no common-mode choke, no X-cap, and no Y-cap. Cross-regulation is tight in spite of having a simple low-cost zener regulation scheme. This document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. Page 3 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 2 Photograph Note the following: • Uses little board space • Uses small transformer: EE25L • Uses small output capacitors • Uses small output diodes • Does not use TL431 • Uses small primary snubber • Does not use linear regulator at 12V. Figure 1 – Power Integrations PSU unit. Page 4 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 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 Symbol Min Typ Max Units Comment VIN fLINE 85 47 265 64 0.3 VAC Hz W 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 3.3 0.48 5.0 0.58 12 0.40 -12 50 0.6 50 0.85 80 0.1 80 0.015 -23 0.01 4.0 400 0.1 0.1 POUT POUT_PEAK η V mV A V mV A V mV A V mV A V mV A V 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 A 9.0 11 72 W W % Measured at full load, 25 oC Environmental Conducted EMI Ambient Temperature Meets CISPR22B / EN55022B TAMB 0 40 o C Free convection, sea level Note 1: Above peak current specs are based on actual DVD board measurements. Actual power supply peak current capability is greater. Page 5 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 21 4 Schematic DER-8 Figure 2 – Schematic. 9W DVD power supply using TNY267P Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com February 4, 2004 DER-8 9W DVD power supply using TNY267P February 4, 2004 5 Circuit Description This circuit is configured as a flyback using the TNY267P. 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 C4. Inductor L1, C1 and C4 form a pi (π) 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 D6, capacitor C5 and resistor R2. 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 D13 and optocoupler U2 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 TNYSwitch 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 5V output is regulated at 1V, and all other outputs are at 1/5th of normal output voltage. The DVD system draws very little current during this output voltage condition. The net result is that the input power is ~200 mW at 230 Vac input. Page 7 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 6 PCB Layout Figure 3 – Printed Circuit Layout. Note: The assembled unit has some component locations not stuffed. Page 8 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 7 Bill Of Materials Item Quantity Reference Part ______________________________________________ 1 2 2 3 4 5 6 7 8 9 10 11 12 1 1 1 1 1 1 1 1 1 1 2 13 14 15 1 1 4 16 17 1 3 18 2 19 20 21 22 23 24 25 1 1 1 1 1 1 2 26 27 1 2 28 29 30 31 32 1 1 1 1 2 33 34 35 36 1 1 1 3 37 2 38 39 40 1 1 1 Page 9 of 21 C4 C1 C2 C5 C8 C10 C11 C12 C15 C16 C17 C18 C19 C20 C21 C22 D1 D2 D3 D4 D5 D6 D7 D8 D11 D10 D12 D13 D15 D16 D17 F1 U2 22uF/400V 22uF/400V 0.01uF 1KV 10uF/35V 2.2nF FY1 0.1uF 50V 470uF/10V 470uF/10V_ZL 270uF/16V 100uF/35V 330uF/10V 220uF/10V_ZL 47uF/35V 47uF/35V 0.1uF/50V 330pF /50V 1N4007GP 1N4007GP 1N4007GP 1N4007GP 1N4007 GP BAV20 BAV20 BAV20 1N5822 1N5822 1N4148 BZX79-B4V7 BZX79-B12V BZX79-B5V1 BZX79-B5V6 1A/250V LTV817A L1 L3 L4 Q4 Q8 R1 R2 R13 R3 R4 R4 R7 R14 R16 R20 R19 R21 R22 R24 R25 1.5mH 3.3uH 3.3uH 3904 3906 200K 1/4W 39K 1R 1/4W 1R 1/4W optional 100 Ohm 100 1/4 W 22K 22K 22K 1M 1/4W 1M 1/4W 10K 24K 1K Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 41 42 43 9W DVD power supply using TNY267P 1 1 1 SW1 T1 U1 February 4, 2004 DC SWITCH OFF EE25L TNY267P Note: All resistors are 1/8W unless otherwise specified. Page 10 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 8 Transformer Specification 8.1 Electrical Diagram 7 11 W6 4T W2 +12 V 60T x 1 Primary 10 W5 3 1T X 3 +5 V NC W3 Shield 8 1T CU FOIL W4 2T X 3 7 +3.3 V 9 2 W1 W7 12T -22 V 14T x 3 Bias 12 1 13 W8 3T F+/14 Figure 4 –Transformer Electrical Diagram. 8.2 Electrical Specifications Electrical Strength 1 second, 60 Hz, from pins 1-7 to pins 8-14 Primary Inductance Pins 3-7, all other windings open. Measured at 132 kHz, 1 VRMS Resonant Frequency Pin 3-7, all other windings open 300 kHz (Min.) Primary Leakage Inductance Pins 3-7, with pins 8-14 shorted. Measured at 132 kHz, 1 VRMS 30 µH (Max.) Page 11 of 21 3000 VAC 1.43 mH +15% Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 8.3 9W DVD power supply using TNY267P Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] 8.4 February 4, 2004 Description 2 Core: EEL25, TDK Gapped for AL of 392 nH/T Bobbin: EEL25 Horizontal 14 pins Magnet Wire: # 25 AWG Magnet Wire: #28 AWG Magnet Wire: #26 AWG Copper Foil 2.0 mils thick, 16 mm wide. Tape: 3M 1298 Polyester Film, 16 mm wide Tape: 3M 1298 Polyester Film, 22 mm wide Margin tape: 3M # 44 Polyester web. 3.0 mm wide Teflon Varnish Transformer Build Diagram 14 13 F-/F+ 12 - 22 V 9 10 11 +12 V 8 5V 3.3V 9 8 7 Shield 10 7 3 1 2 Primary Bias Figure 5 – Transformer Build Diagram. REV B Page 12 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 8.5 9W DVD power supply using TNY267P February 4, 2004 Copper Foil Preparation TAPE 22mm wide COPPER FOIL 16mm W X 100mm L x 2mils THICK TEFLON TUBE #32 AWG WIRE Figure 6 – Foil Winding Preparation Diagram. 8.6 Winding Instructions 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. Page 13 of 21 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 2 using item [10] at the finish leads. Flip the starting lead over to pin 1 using item [10] at the finish lead. Apply 1 layers of tape item [7] Start on pin 3 using item [10] at the start leads. Wind 30 turns of item [3] from left to right. Wind another 30 turns from right to left in second layer. Finish on pin 7 using item [10] at the finish leads. Apply 1 layers of tape item [7] Start on pin 7 using item [10] at the start leads. Wind 1 turns of copper shield shown in figure 7. 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 8 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 9 using item [10] at the finish leads. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P W5 +5V Winding Basic Insulation W6 +12 Winding Basic Insulation W7 -22 V Winding W8 F- / F+ Winding Outer Insulation Core Assembly Final Varnish Page 14 of 21 February 4, 2004 Start on pin 10 using item [10] at the start leads. Wind 1 trifilar turn of item [5]. Wind the wire between 3.3V windings. Finish on pin 8 using item [10] at the finish leads. Apply one layer of tape item [7] Start at pin 11 using item [10] at the start leads. Wind 4 turns of item [4]. Wind uniformly spread across the bobbin. Finish at pin 10 using item [10] at the finish leads. Apply one layer of tape item [7] Start at pin 9 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 12 using item [10] at the finish leads. Start at pin 13 using item [10] at the start leads. Wind 3 turns of item [4]. Finish at pin 14 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 [11] Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 9 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency Units were loaded as follows: 0.6A@5V; [email protected]; 0.1A@12V; 10mA@-12V; 0.1A@22V. Full load Efficiency Percent Efficiency (%) 80.00 75.00 70.00 65.00 60.00 Unit #1 Unit #2 55.00 50.00 90 120 150 180 210 240 270 Ac Input Voltage (VAC) Figure 7- Efficiency vs. Input Voltage, Room Temperature, 60 Hz. Page 15 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9.2 9W DVD power supply using TNY267P February 4, 2004 Standby Input Power at 2W load. Stand-by Efficiency Percent Efficiency (%) 80.00 75.00 70.00 65.00 60.00 Unit #1 Unit #2 55.00 50.00 90 120 150 180 210 240 270 Ac Input Voltage (VAC) Figure 8- Standby Input Power vs. Input Line Voltage Page 16 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9.3 9W DVD power supply using TNY267P February 4, 2004 Cross Regulation The tests were done at room temperature at minimum and maximum input voltage. 9.3.1 Play Mode Load Combination 1: 0.56A@5V; [email protected]; 40mA@12V; 15mA@-12V; 10mA@22V Output Vin@90V Vin@265V UNIT #1 UNIT #2 UNIT #1 UNIT #2 3.3 V 3.35 3.29 3.34 3.36 5V 5.17 5.08 5.28 5.18 +12 V 12.65 12.48 12.99 12.83 -12 V -12.16 -12.0 -12.78 -12.66 -23 V -22.87 -22.8 -23.49 -23.46 Load Combination 2: 0.85A@5V; [email protected]; 40mA@12V; 15mA@-12V; 10mA@22V Output Vin@90V Vin@265V UNIT #1 UNIT #2 UNIT #1 UNIT #2 3.3 V 3.4 3.33 3.47 3.42 5V 5.15 5.05 5.24 5.16 +12 V 12.81 12.64 13.11 13.0 -12 V -12.6 -12.48 -13.12 -13.13 -23 V -23.31 -23.28 -23.83 -23.94 Load Combination 3: 0.85A@5V; [email protected]; 100mA@12V; 15mA@-12V; 100mA@22V Output Vin@90V Vin@265V UNIT #1 UNIT #2 UNIT #1 UNIT #2 3.3 V 3.37 3.32 3.46 3.4 5V 5.14 5.06 5.27 5.18 +12 V 12.26 12.06 12.55 12.33 -12 V -11.15 -11.0 -11.63 -11.27 -23 V -21.86 -21.61 -22.34 -22.06 Page 17 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 9.3.2 Stand-by Mode Load Combination 4: 110mA@5V; [email protected]; 15mA@12V; 15mA@-12V; 1mA@22V Output Vin@90V Vin@265V UNIT #1 UNIT #2 UNIT #1 UNIT #2 3.3 V 3.44 3.37 3.5 3.44 5V 5.23 5.14 5.31 5.23 +12 V 12.4 12.15 12.66 12.40 -12 V -11.1 -10.73 -11.55 -11.18 -23 V -21.82 -21.53 -22.26 -21.98 Page 18 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 10 Conducted EMI EMI was tested at room temperature, 230 VAC input, at Load Combination 2: 0.85A@5V; [email protected]; 100mA@12V; 15mA@-12V; 100mA@-22V. Figure 9 – LINE, Secondary Ground Connected to Earth. Unit#2 Figure 10 - LINE, Secondary Ground NOT Connected to Earth. UNIT#2 Page 19 of 21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 9W DVD power supply using TNY267P February 4, 2004 11 Revision History Date February 4, 2004 Page 20 of 21 Author ME Revision 1.0 Description & changes Initial release Reviewed AM/VC Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-8 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. © 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: [email protected] 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: [email protected] 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: [email protected] SINGAPORE Power Integrations, Singapore 51 Goldhill Plaza #16-05 Republic of Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: [email protected] 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: [email protected] 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: [email protected] APPLICATIONS HOTLINE World Wide +1-408-414-9660 APPLICATIONS FAX World Wide +1-408-414-9760 Page 21 of 21 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: [email protected] INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore, India 560052 Phone: +91-80-226-6023 Fax: +91-80-228-9727 e-mail: [email protected] Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com