Power Integrations - Design Example Report

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
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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
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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
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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
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Page 6 of 21
4 Schematic
DER-8
Figure 2 – Schematic.
9W DVD power supply using TNY267P
Power Integrations
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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
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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
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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
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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
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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%
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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
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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.
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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]
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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
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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
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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
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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
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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
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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
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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.
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