Title Engineering Prototype Report – 3 W Universal Input TinySwitch-II TNY264 Power Supply Specification 3 W, (9 V, 0.33 A), 85–265 VAC input Target Applications AC Adapters (cordless phones, answering machines and other consumer products) Author Power Integrations Applications Dept. Doc Num. EPR-000014 Date 22 Feb 2002 Revision 1.3 Features • • • • • • • • • • • • Cost effective (minimum parts count and single sided PC board) Low Cost EF12.6 transformer (132 kHz operation) Compact design: 2.0” x 1.2” x 0.75” No-load consumption < 250mW (230 VAC) Auto-restart function limits overload output power Short circuit protected Built-in circuitry practically eliminates audible noise (standard varnished transformer) ON/OFF control allows simple Zener reference and eliminates the need for loop compensation No-load regulation achieved without preload resistor Low EMI due to frequency jittering: meets CISPR22B with output capacitively grounded Optional under-voltage detect eliminates power-up glitches Hysteretic thermal shutdown: Protects power supply and automatically recovers when fault is removed Power Integrations, Inc. 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 Table of Contents 1 2 3 4 5 6 7 Introduction ................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic ................................................................................................................... 5 Description.................................................................................................................. 5 PCB Layout................................................................................................................. 7 Bill of Materials ........................................................................................................... 7 Transformer Specification........................................................................................... 8 7.1 Electrical Specifications .......................................................................................... 8 7.2 Materials.................................................................................................................. 8 7.3 Transformer Diagram .............................................................................................. 9 7.4 Transformer Construction ....................................................................................... 9 7.5 Transformer Sources............................................................................................... 9 8 Performance Data..................................................................................................... 10 8.1 Output Regulation ................................................................................................. 10 8.2 Efficiency............................................................................................................... 11 8.3 Standby Power Consumption ................................................................................ 11 8.4 Output Overload.................................................................................................... 12 8.5 Thermal Performance............................................................................................ 12 8.6 Conducted Emissions............................................................................................ 14 8.7 Acoustic Emissions ............................................................................................... 16 9 Waveform Scope Plots ............................................................................................. 18 9.1 Output Ripple Measurement Results .................................................................... 18 9.1.1 DC Ripple Measurement Technique .............................................................. 19 9.2 DC Output Load Transient Response ................................................................... 20 9.2.1 10% to 50% load change, 265 VAC................................................................. 20 9.2.2 10% to 100% load change, 265 VAC............................................................... 20 9.3 Turn-On Delay and Overshoot .............................................................................. 21 9.4 Drain Switching Waveforms .................................................................................. 22 9.4.1 85 VAC, Full load, 132 kHz operation.............................................................. 22 9.4.2 85 VAC, Full load, ~100 kHz operation............................................................ 22 9.4.3 265 VAC, Full load, 132 kHz operation............................................................ 23 9.4.4 265 VAC, Full load, ~60 kHz operation............................................................ 23 10 AC Surge and 100 kHz Ring Wave Immunity ........................................................... 24 10.1 Differential Mode Surge Test Results................................................................ 24 10.2 Common Mode Surge Test Results................................................................... 25 10.3 Differential Mode 100 kHz Ring Wave Test Results ......................................... 25 10.4 Common Mode 100kHz Ring Wave Test Results ............................................. 26 11 Revision History........................................................................................................ 27 Important Note: Although the EP14 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. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 1 Introduction This document is an engineering report that describes a 9 V, 0.33 A, 3 W output and universal input power supply utilizing the TNY264P. For evaluation, a fully built and tested prototype (EP14) can be found within the Design Accelerator Kit, DAK-14. This document contains the power supply specification, schematic, bill of materials and transformer documentation. Typical operating characteristics are presented at the rear of the report and consist of performance curves, tables and waveform photos. 1.2” / 30.5 mm 2” / 51.5 mm Figure 1. EP14 Populated Circuit Board (approx. 2:1 scale) Page 3 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 2 Power Supply Specification Description Input Input Voltage Input Frequency No-load Input Power (115 VAC) No-load Input Power (230 VAC) Output Output Voltage Output Ripple Voltage Output Current Continuous Output Power Symbol Min Typ Max Units VIN fLINE 85 47 115/230 50/60 265 64 125 250 VAC Hz mW mW VOUT VRIPPLE IOUT POUT 8.37 VDC † mVPK-PK A W (± 7%) At output terminals 20 MHz BW 0 0 9.63 100 0.33 3.0 -2 +2 % 0 – 100% load 85 – 265 VAC At full load Total Regulation Efficiency Environmental Conducted EMI Safety External Ambient Temperature † η 67 71 Comment Meets CISPR22 B Designed to meet IEC950 T AMB 0 50 o C Natural convection Output voltage tolerance may be improved through choice of feedback components Table 1. Power Supply Specification Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 3 Schematic Figure 2. EP14 Power Supply Schematic 4 Description The EP14 is a single 9 VDC output power supply rated at 3 W. The power supply was designed to operate over an AC input range of 85-265 VAC, 47-64Hz and provides 9 VDC output with ±7% accuracy to no-load. Operating efficiency is 67% worst case at full load across the entire AC line range. Compliance to CISPR22 / EN55022 Class B conducted emissions and surge immunity test level 1 (1 kV, 1.2 / 50 µS - IEC1000-4-5) is achieved with minimum component count. The unit is designed to comply with international safety standards per IEC950. Minimum parts count enables a space conscious design, with outside dimensions 1.2” x 2.0” x 0.75”. TinySwitch-II provides several advantages in this application. The enhanced ON/OFF control scheme allows tight regulation using a simple, low-cost secondary side Zener reference and no loop compensation. No-load regulation is achieved without a dummy load. The enhanced ON/OFF control scheme dynamically alters the internal current limit as load requirements dictate. This approach reduces cycle skipping when the core flux density is high; thus minimizing acoustic noise. This eliminates the need for special construction, the transformer merely needs to be dip varnished. Increased operating frequency (132 kHz) allows the use of a small EF12.6 core, while frequency jittering reduces conducted emissions and resulting filtering requirements. These features, combined with primary-side transformer shielding, allows EP14 to comply with CISPR22 B (FCC Class B) emissions without the use of a large, expensive Page 5 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 common mode input choke. Class B emissions are achieved for applications requiring an ‘artificial hand’ tied to secondary return; which makes this design fully compliant with handheld applications. Standby power consumption is below 250 mW at 230 VAC input. TinySwitch-II provides greatly reduced device tolerances and incorporates built-in hysteretic overtemperature protection. These features minimize component count while maximizing device power capability. Auto-restart functionality minimizes device thermal stresses during short-circuit conditions; providing performance similar to that available with the TOPSwitch families. A fusible, flameproof resistor (R1) is used in place of a fuse to reduce cost and increase differential mode filtering. This, combined with the π filter formed by L1, C1 and C2 in addition to C5, allows the unit to meet EN55022 B (CISPR22 B) conducted emission standards. The AC input is rectified and smoothed by D1-4, C1 and C2. The resulting DC bus is applied to one end of the transformer primary. The other end of the primary is connected to the TinySwitch-II DRAIN pin. Low cost RCD clamping (R4, C3 & D6) limits the maximum DRAIN voltage to below 700 V due to transformer leakage inductance. C4 provides the local bypass for TinySwitch-II. This capacitor is kept charged during the off time of the internal MOSFET, providing the energy to supply the IC. An optional line sense resistor (R3) implements under-voltage detect. This is accomplished by sensing the DC voltage across the bulk input capacitors (C1 &C2) at power-up. TinySwitch-II is disabled until the DC voltage reaches the required level. With R3 as shown (2 MΩ) this occurs at 100 VDC. Under-voltage detect ensures that the outputs are glitch free on power-up and power down, preventing the power supply from starting if the input voltage is too low, and stopping the supply when the output falls out of regulation on power down. TinySwitch-II will detect the absence of R3 and disable the under-voltage function if not required. The secondary is rectified by D6 and C6. Second stage output filtering consists of ferrite bead (L2) and output capacitor (C7) which eliminate high frequency switching noise and reduce output ripple below 100 mVp-p. VR2 and U2 sense the output voltage. The combined voltage drop of these two components sets the output voltage to 9 V. A 5% Zener was used giving an overall tolerance and regulation variation of ±7%. Using a 3% or 2% Zener allows a more tightly controlled output voltage tolerance. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 5 PCB Layout Figure 3. PCB Layout (2.0 × 1.2 × 0.75”) 6 Bill of Materials Item Quantity Number 1 2 2 1 3 1 4 1 5 1 6 1 7 4 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 Value 4.7 uF, 400 V 2.2 nF, 1 kV, Z5U 0.1 uF, 50 V 2200 pF, Y1, 250 V 330 uF, 16 V, HFQ 220 uF, 25 V, NHE 1N4007 1N4937, 1 A, 600 V 11DQ06, 1.1 A, 60 V 1 mH Bead 8R2, fusible, flameproof 4.7 kΩ, 1/8W 2 MΩ, 1/2W 330 kΩ, 1/2W Transformer, EF12.6 TNY264P LTV817A BZX79-C8V2, 5% Part Reference Manufacturer C1, C2 C3 C4 C5 C6 C9 D1, D2, D3, D4 D5 D6 L1 Tokin L2 Fair-rite R1 Vitrohm R2 R3 *optional for UV detect R4 T1 Hical U1 U2 VR2 Note: assumes 5% resistors Page 7 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 7 Transformer Specification 1 8 10T # 28 AWG (0.3 mm) TIW 96T #33 AWG (0.18 mm) 5 3 2 10T 2x #33AWG (0.18 mm) 1 7.1 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.2 60 Hz 1minute, from Pins 1-3 to Pins 5-8 All windings open, from Pins 1-3 All windings open, from Pins 1-3 Pins 1-3, from Pins 5-8 shorted 3000 VAC 1250 µH ±20% 700 kHz (Min.) < 50 µH Materials Item [1] [2] [3] [4] [5] [6] Description Core: EF12.6, Gapped for AL of 135nH/T2 Bobbin: Hical EF12.6, 8P Magnet Wire: # 33 AWG (0.18 mm) Double Nyleze Magnet Wire: # 28 AWG (0.3 mm) Triple Insulated Tape: 3M 1298 Polyester Film (white) 7.8mm wide by 2.2 mils (0.06mm) thick Varnish Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 28 22-Feb-2002 7.3 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter Transformer Diagram 5 8 Secondary Tape 2 Shield 1 Tape 1 Primary 3 7.4 Transformer Construction Primary Layer Insulation Shield Winding Insulation Secondary Winding Final Assembly Start at Pin 3. Wind 33 turns of item [3] from left to right. Wind 33 turns in the next layer from right to left. Wind remaining 30 turns in the next layer from left to right. Finish on Pin 1. 1 Layer of tape [5] for insulation. Continue at Pin 1. Wind 10 turns of bifilar item [3] from left to right. Wind uniformly, in a single layer, across entire width of bobbin. Finish on Pin 2. 1 Layers of tape [5] for insulation. Start at Pin 8. Wind 10 turns of item [4] from right to left. Wind uniformly, in a single layer, across entire width of bobbin. Finish on Pin 5. Assemble and secure core halves. Impregnate uniformly (dip varnish) [6] and bake. 7.5 Transformer Sources For information on the vendors used to source the transformer, please visit our website at the address below and select Engineering Prototype Boards http://www.powerint.com/componentsuppliers.htm Page 9 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 8 Performance Data Performance data was collected on a single prototype unit (UUT2) at room temperature, unless specified otherwise. Testing was done using a programmable AC generator, Kikusui PLZ-72W electronic load and high resolution AC wattmeter. Details of the test set-up are available in the individual sections. 8.1 Output Regulation AC source set at 50 Hz with a DC load and a DC ammeter. DC regulation data represents the deviation on the output channel across the full load range (no load – 0 A, ½ load - 0.17 A and full load - 0.33 A) and while varying AC input (85 – 265 VAC). Output voltage transitions may occur when shifting between operating modes; producing a slight deviation to the curve fit presented. Output Load Regulation Output Deviation (%) 2.50% 2.00% 85/115VAC 1.50% 230/265VAC 1.00% 0.50% 0.00% 0 0.1 0.2 0.3 Output Current (A) Figure 4. Output Load Regulation vs AC Line Voltage Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 8.2 Efficiency Efficiency data was collected at full load while varying the AC input, 50 Hz line frequency. Thermal stabilization was verified. Data represents worst-case efficiency in high frequency operating mode. Due to capacitive switching losses, high voltage efficiency is reduced in high frequency mode (132 kHz). Efficiency 78.0% Efficiency (%) 76.0% 74.0% 72.0% 70.0% 68.0% 85 135 185 235 Input Voltage (VAC) Figure 5. Supply Efficiency vs Line Voltage 8.3 Standby Power Consumption Standby power was measured with output load disconnected utilizing a high resolution AC wattmeter after the supply had thermally stabilized Standby Power Loss 0.25 Dissipation (W) 0.2 0.15 0.1 0.05 0 75 95 115 135 155 175 195 215 235 255 275 Input VAC Figure 6. Supply Standby Power vs Line Voltage Page 11 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 8.4 Output Overload The following curve shows results with the output overload, at room ambient. Output load was adjusted to obtain maximum continuous output current while varying the AC line input. The power supply will operate in auto-restart mode when maximum output current is exceeded. A reduction in maximum output current and input power can be expected as operating temperature is increased. Maximum Output Current vs AC Input 12 0.9 10 0.7 0.6 8 0.5 6 0.4 0.3 4 IOUT max PIN 0.2 Input Power (W) Output Current (A) 0.8 2 0.1 0 0 85 120 200 230 265 VAC Input Figure 7. Maximum Output Current vs Line Voltage 8.5 Thermal Performance Thermal data was collected at room temperature and raised ambient with natural convection, no power supply enclosure, and at a full load of 3 W with the AC line varied. All temperatures were recorded with T-type thermocouples and represent the temperature rise over power supply external ambient, in degrees Celsius (+°C). • • • • • Transformer measured on core, outer leg (glued between core leg and output windings) TNY264P soldered to Source lead (pin 2) All other thermocouples glued to component body Local power supply ambient air temperature was monitored The following data represents worst-case dissipation, operating at 132 kHz mode(s) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 28 22-Feb-2002 VAC 85 115 230 265 85 265 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter DAK-14 Component Temperature Rise (+°C) T1 L1 PIN (W) TAMB TNY264P core inductor 4.08 25 34.9 26.7 9.5 4.01 25 32.1 26.0 8.9 4.16 25 39.9 28.3 9.5 4.27 25 47.8 31.7 10.2 4.16 50 34.7 21.8 9.8 4.35 50 46.2 27.7 10.0 C4 capacitor 16.9 17.6 18.7 19.1 16.1 17.5 Table 2. Key Component Thermal Rise Data Figure 8. Infra Red Scan of DAK-14, 25 °C Ambient These results indicate that this is an optimum thermal design. The TNY264 is the hottest component with a 46 °C rise above ambient. This gives an acceptable device temperature of ~100 °C at an external ambient of 50 °C. Page 13 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 8.6 Conducted Emissions The following conducted emissions scans were recorded operating at full load (resistive 3 W), 115/230 VAC, 60 Hz. A two-wire AC cord was used. In all cases the ‘artificial hand’ connection of the LISN was tied to secondary side RTN. The worst-case phase was recorded (conducted emissions on alternate phase typically varies 1-2 dBµV). Rohde & Schwarz Model ESPC receiver and LISN Model ESH3-Z5. In all cases it was verified that the TNY264 operated at full frequency (132 kHz), to ensure worst-case results. Line emissions were measured across the frequency range. Pre-scan sweeps for each detector type are presented, Quasi-Peak (top / blue) and Average (bottom / green). Limit lines for CISPR 22 (EN55022) Class B Quasi-Peak (top / red) and Average (bottom / magenta) are visible. Any peak within 15 dB of the limit line was verified with a 1sec measurement. These results are shown on the scans (Figures 9 & 10) as a red cross (×) or a magenta plus (+). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter QP Limit AV Limit Quasi Peak Average Figure 9. Conducted Emissions, 115 VAC Line QP Limit AV Limit Quasi Peak Average Figure 10. Conducted Emissions, 230 VAC Line A 2-3 dBµV reduction in broadband emissions is obtained with the ‘artificial hand’ disconnected. Increased emissions can be expected with secondary RTN tied to the LISN ground connection (PE). Page 15 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 8.7 Acoustic Emissions The power supply was subjected to acoustic emissions measurement. The worst-case noise was measured for variations of both AC line and output loading conditions. These results are presented in Figure 12 and Figure 13. In all cases, acoustic emissions were below acceptable levels. The test unit was placed in an anechoic acoustic chamber, with a microphone located approximately 1” (25 mm) above the transformer (T1) as shown in Figure 11. The power supply was oriented in a horizontal position with the power supply output loaded via an external Kikusui electronic load. The microphone output was fed to an Audio Precision audio analyser to provide the measurements shown. Microphone Figure 11. Test Arrangement for Audio Noise Measurement The curves shown indicate the spectral content of the noise generated by the supply once the ANSI-A weighting factor has been applied. The audio limit line (Figure 12, 13) visible at +35 dB represents the generally accepted threshold for power supply audio noise. A discrete audio frequency amplitude was used rather than a dBA value (dBA represents the whole audio spectrum). Large peaks may not raise the dBA value yet can result in unacceptable perceived noise. As a reference, the approximate dBA background noise floor level is 30 dBA. The microphone sensitivity is such that 20 µP = 0 dB SPL. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter Up to a further 20 dB reduction can be expected, from the measurement shown, once the power supply is sealed inside an enclosure. Figure 12. Acoustic Emissions Spectrum, 230 VAC Input, 9 V, 0.21 A Output Figure 13. Acoustic Emissions Spectrum, 230 VAC Input, 9 V, 0 A Output Page 17 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 9 Waveform Scope Plots The following bench data was collected with a Yokogawa DL1540L oscilloscope, Kikusui electronic load and at an AC input frequency of 50 Hz. 9.1 Output Ripple Measurement Results Output ripple measurement at worst-case 265 VAC is presented across the loading range, 20 MHz oscilloscope bandwidth. In all cases, output ripple is maintained below 100 mVp-p. See Figure 15 for details of scope probe. The output ripple waveshape is a function of AC input voltage and load and may vary with the TNY264 operating mode. VOUT_AC Load: 0% / 0 A VOUT_AC Load: 50% / 0.17 A VOUT_AC Load: 100% / 0.33 A Figure 14. Output Ripple (265 VAC, 0 A, 0.17 A & 0.33 A Loading, 50 mV/div) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 9.1.1 DC Ripple Measurement Technique Details of output ripple probe are provided below. Decoupling capacitors are included to minimize the effects of high frequency probe coupling and ensure a consistent measurement setup. Probe RTN Probe Tip Figure 15. Tektronix P6105A Oscilloscope Probe with Probe Master 5125BA BNC adapter, modified with wires for Probe Ground for ripple measurement. Two parallel decoupling capacitors have been added (1.0 µF, 50 V aluminum electrolytic and a 0.1 µF, 50 V ceramic) Page 19 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 9.2 DC Output Load Transient Response Worst case transient measurements were obtained with a Kikusui electronic load and a Yokogawa DL1540L oscilloscope (20 MHz bandwidth) during output load steps at 265 VAC. The transient response exhibits negligible overshoot. 9.2.1 10% to 50% load change, 265 VAC VOUT_AC IOUT Figure 16. Transient Response 265 VAC 50 Hz, IOUT: 0.03 A to 0.17 A VOUT & IOUT (100 mV & 200 mA/div, 2 ms/div) 9.2.2 10% to 100% load change, 265 VAC VOUT_AC IOUT Figure 17. Transient Response 265 VAC 50 Hz, IOUT: 0.03 A to 0.33 A VOUT & IOUT (100 mV & 200 mA/div, 2 ms/div) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 9.3 Turn-On Delay and Overshoot Turn-on delay was recorded as referenced to the DRAIN-SOURCE voltage. A resistive load is recommended to avoid incorrect results when using electronic loads. In all cases, overshoot is negligible and turn-on delay is less than 8 ms, worst-case. VOUT_DC VDRAIN Figure 18. Start-up, 0.33 A Load, 85 VAC VOUT & VDRAIN (5 & 200 V/div, 2ms/div) VOUT_DC VDRAIN Figure 19. Start-up, 0.33 A Load, 265 VAC VOUT & VDRAIN (5 & 200 V/div, 2ms/div) Page 21 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 9.4 Drain Switching Waveforms The following waveforms detail DRAIN-SOURCE voltage and current at full load while varying the AC input. The operating mode of the TNY264 can vary under identical operating conditions. The waveforms display both the high and low switching frequencies possible under identical operating conditions. Actual operating mode depends on magnetizing inductance (LP), current limit (ILIM), together with line voltage and load. 9.4.1 85 VAC, Full load, 132 kHz operation VDRAIN IDRAIN Figure 20. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 85 VAC Input. (5 µs/div) 9.4.2 85 VAC, Full load, ~100 kHz operation VDRAIN IDRAIN Figure 21. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 85 VAC Input. (5 µs/div) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 9.4.3 265 VAC, Full load, 132 kHz operation VDRAIN IDRAIN Figure 22. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 265 VAC Input. (5 µs/div) 9.4.4 265 VAC, Full load, ~60 kHz operation VDRAIN IDRAIN Figure 23. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 265 VAC Input. (5 µs/div) Page 23 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 10 AC Surge and 100 kHz Ring Wave Immunity Running at full load (resistive 3 W), 115 and 230 VAC, 60 Hz. the power supply was subjected to repeated high voltage AC Surge (IEC 1000-4-5) and Ring Wave tests (IEEE C62.41). These included both common mode and differential mode injection. A Keytek EMCPro was utilized with a 2 Ω/12 Ω source impedance (as indicated). In typical adapter applications immunity to 1 kV (IEC 1000-4-5, class 2) would be required. From the results below it can be seen that this is exceeded. To monitor power supply status, LED were connected across the DC output. Evaluation was completed with reference to the following: Pass Blink Latch-up Fail Normal performance within specification limits Temporary degradation (PSU glitches - LED blink) Temporary degradation with operator intervention (PSU stops - LED turns off, but returns with AC cycle) Permanent, unrecoverable degradation (power supply and/or component damage) Conditions were a single sample (UUT4) with tests performed in the order indicated. Corrective action between test failures were as indicated. The environmental conditions were a room ambient of 23 °C with ~70 % humidity, a repetition rate 1of 5 s, an internal trigger and 90° phase injection. 10.1 Differential Mode Surge Test Results The results for differential mode surge immunity testing are shown below (IEC 1000-4-5, 1.2/50 µs - 8/20 µs, L-N). For differential mode tests, a two-wire AC cord was utilized. AC Ground (PE) was disconnected. There was a 2 Ω generator source impedance. Compliance beyond Class 3 (1 kV), with no degradation, was confirmed. Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 -2000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Fail n/a Test Sequence 1 2 3 4 5 6 7 8 Table 3. Differential Mode Surge Test Results Differential Surge failure at +2 kV required replacement of input fusible resistor (R1), TNY264P (U1) and transformer (T1). Testing was completed on UUT4. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 10.2 Common Mode Surge Test Results The results for common mode surge immunity testing are shown below (IEC 1000-4-5, 1.2/50 µs - 8/20 µs, L/N-G). For common mode tests, a three-wire AC cord was utilized. AC Ground (PE) was tied from AC outlet to power supply output RTN through a copper strap. There was a 2 Ω generator source impedance. Compliance beyond Class 3 (2 kV), with no degradation, was confirmed. Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 +2000 +3000 -3000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Test Sequence 1 2 3 4 5 6 7 8 9 10 Table 4. Common Mode Surge Testing Results Y-capacitor verified prior to proceeding with immunity testing. 10.3 Differential Mode 100 kHz Ring Wave Test Results The results for differential mode 100 kHz Ring Wave immunity testing are shown below (IEEE C62.41, L-N). For differential mode tests, a two-wire AC cord was utilized. AC Ground (PE) was disconnected. There was a 12 Ω generator source impedance. Compliance to 3 kV, with no degradation, was confirmed. Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 +2000 +3000 -3000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Test Sequence 1 2 3 4 5 6 7 8 9 10 Table 5. Differential Mode 100 kHz Ring Wave Test Results Page 25 of 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 10.4 Common Mode 100kHz Ring Wave Test Results The results for common mode 100 kHz Ring Wave immunity testing are shown below (IEEE C62.41, L/N-PE). For common mode tests, a two wire AC cord was utilized. AC Ground (PE) was tied from AC outlet to power supply RTN through a copper strap. There was a 12 Ω generator source impedance. Compliance to 3 kV, with no degradation, was confirmed. Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 +2000 +3000 -3000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Test Sequence 1 2 3 4 5 6 7 8 9 10 Table 6. Common Mode 100 kHz Ring Wave Test Results Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 28 22-Feb-2002 EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 11 Revision History Date 09-Feb-2001 21-Feb-2001 26-Feb-2001 15-Mar-2001 20-Mar-2001 Author SH SH SH SH PV Revision 0.1 0.2 0.3 1.0 1.1 02-Apr-2001 PV 1.2 22-Feb-2002 PV 1.3 Page 27 of 28 Description & changes Original draft Update new transformer results Format changes, rev thermal results Format changes Format changes – audio noise set photo added Spelling and formatting errors corrected p.6 – reference to D6 corrected to read D5 in fourth paragraph Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com EPR-000014 – 9 V, 0.33 A, 3 W TNY264 Adapter 22-Feb-2002 For the latest updates, visit our website: 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. PI Logo, TOPSwitch and TinySwitch are registered trademarks of Power Integrations, Inc. ©Copyright 2001, Power Integrations, Inc. WORLD HEADQUARTERS NORTH AMERICA - WEST Power Integrations, Inc. 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 NORTH AMERICA - EAST & SOUTH AMERICA Power Integrations, Inc. Eastern Area Sales Office 1343 Canton Road, Suite C1 Marietta, GA 30066 USA Phone: +1•770•424•5152 Fax: +1•770•424•6567 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 TAIWAN Power Integrations International Holdings, Inc. 2F, #508, Chung Hsiao E. Rd., Sec. 5, Taipei 105, Taiwan Phone: +886•2•2727•1221 Fax: +886•2•2727•1223 CHINA Power Integrations, China Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu Shenzhen Guangdong, 518031 Phone: +86•755•377•9485 Fax: +86•755•377•9610 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 JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222, Japan Phone: +81•45•471•1021 Fax: +81•45•471•371 INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore 560052, India Phone: +91•80•226•6023 Fax: +91•80•228•9727 APPLICATIONS HOTLINE World Wide +1•408•414•9660 APPLICATIONS FAX World Wide +1•408•414•9760 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 28