® TinySwitch-II Family Enhanced Energy Efficient Low Power Off-line Switcher IC JUNE 2004 PRODUCT HIGHLIGHTS • Fully integrated auto-restart for short circuit and open loop fault protection–saves external component costs • Programmable line under-voltage detect feature prevents power on/off glitches–saves external components • Frequency jittering dramatically reduces EMI (~10 dB)–minimizes EMI filter component costs • 132 kHz operation reduces transformer size–allows use of EF12.6 or EE13 cores for low cost and small size • Built-in circuitry practically eliminates audible noise with ordinary dip-varnished transformer NEW! TNY263 and TNY265 Family Members Expand the Coverage for Low Power Applications FEATURES & BENEFITS TYPICAL FLYBACK APPLICATION + + Optional UV Resistor BETTER COST/PERFORMANCE OVER RCC & LINEARS • Very tight tolerances and negligible temperature variation on key parameters eases design and lowers cost • Expanded scalable device family for low system cost • Lower system cost than RCC, discrete PWM and other integrated/hybrid solutions • Cost effective replacement for bulky regulated linears • Simple design practically eliminates rework in manufacturing Wide-Range HV DC Input ® EcoSmart - EXTREMELY ENERGY EFFICIENT • No load consumption <50 mW with bias winding and <250 mW without bias winding at 265 VAC input • Meets Blue Angel, Energy Star, and EC requirements • Ideal for cell-phone charger, DVD player, and PC standby applications D EN/UV BP TinySwitch-II S PI-2684-101700 HIGH PERFORMANCE AT LOW COST • Simple ON/OFF control–no loop compensation needed • No bias winding–simpler, lower cost transformer • High voltage powered–ideal for charger applications • High bandwidth provides fast turn on with no overshoot • Current limit operation rejects line frequency ripple • Built-in current limit and thermal protection improves safety DC Output OUTPUT POWER TABLE PRODUCT TNY263 P or G 230 VAC ±15% Open Adapter Frame 5W 7.5 W 85-265 VAC Open Adapter Frame 3.7 W 4.7 W TNY264 P or G 5.5 W 9W 4W 6W TNY265 P or G 8.5 W 11 W 5.5 W 7.5 W TNY266 P or G 10 W 15 W 6W 9.5 W TNY267 P or G 13 W 19 W 8W 12 W TNY268 P or G 16 W 23 W 10 W 15 W See Data Sheet for Additional Notes and Conditions. www.powerint.com P = DIP-8 G = SMD-8 June 2004 ® TinySwitch-II Family Design Tools POWER SUPPLY DESIGN SOFTWARE With PI Expert™, you’re only “mouse-clicks” away from determining the key components in your next switching power supply design, including the best Power Integrations power IC and design details for the transformer! It’s fast & easy...and best of all, FREE! DESIGN ACCELERATOR KIT (DAK) DAKs include a working prototype power supply, sample devices, unpopulated pcb, data sheet, comprehensive engineering report & other related documentation. DAK-14A 3 W, 9 V Universal Input Charger/Adapter TinySwitch-II PRODUCT & DESIGN COLLATERAL* Data Sheet Design Ideas1 Engineering Prototype Reports2 Design Example Reports3 TNY263-268 DI-77 DI-63 DI-62 DI-61 DI-34 DI-33 DI-28 DI-13 DI-11 EPR-62 EPR-29 EPR-14 EPR-9 DER-35 DER-33 DER-11 DER-10 DER-09 DER-08 DER-07 DER-06 DER-05 DER-04 DER-03 TinySwitch-II Family Data Sheet Application: Charger/Adapter (3 W, 9 V, Universal Input), <200 mW No-load Application: Charger/Adapter (4.8 W, 6 V, Universal Input) Application: Charger/Adapter (3 W, 5 V, Universal Input), <30 mW No-load Application: Charger/Adapter (3 W, 5 V, Universal Input), <200 mW No-load Application: Charger/Adapter (5 W, 5 V, Universal Input) Application: DVD Player (11 W, 17 W Peak, 3.3 V / 5 V / 12 V / -12 V, Universal Input) Application: Charger/Adapter (3 W, 5 V, Universal Input), <30 mW No-load Application: Charger/Adapter (3 W, 9 V, Universal Input) Application: General Purpose (1.2 W, 12 V, Universal Input Buck Converter) Application: Charger/Adapter (3 W, 5 V, Universal Input), <30 mW No-load Application: DVD Player (11 W, 15.5 W Peak, 3.3 V / 5 V / 12 V / -12 V, Universal Input) Application: Charger/Adapter (3 W, 9 V, Universal Input) (DAK-14) Application: Appliance (5 W, 5 V / 12 V, Universal Input) Application: Charger/Adapter (3.5 W, 5.5 V, Universal Input) Application: Charger/Adapter (3.9 W, 6.5 V, Universal Input), <80 mW No-load Application: PC Standby (15 W, 5 V / 13 V) Application: DVD Player (4.9 W, 8.5 W Peak, 5 V / 3.3 V / 12 V / -12 V, Universal Input) Application: DVD Player (4.4 W, 5.7 W Peak, 5 V / 3.3 V / 12 V / -12 V, Universal Input) Application: DVD Player (9 W, 11 W Peak, 5 V / 3.3 V / 12 V / -12 V / -22 V / 4 V, Universal Input) Application: DVD Player (9 W, 10.5 W Peak, 5 V / 3.3 V / 12 V / -12 V / -23 V / 3 V, Universal Input) Application: Charger/Adapter (3.6 W, 5.1 V, Universal Input) Application: DVD Player (11 W, 17 W Peak, 3.3 V / 5 V / 12 V / -12 V) Application: Charger/Adapter (2.4 W, 6 V, Universal Input) Application: Charger/Adapter (2.4 W, 6 V, Universal Input) 1. Design Ideas (DI) - Design Ideas are two-page documents describing real world applications using Power Integrations’ ICs. All necessary information is provided for building the circuit. 2. Design Example Report (DER) - Design Example Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. This design has had very limited production (typically a one-off design). 3. Engineering Prototype Report (EPR) - Engineering Prototype Reports contain a power supply reference design specification, schematic, bill of materials and transformer documentation. Performance data and typical operating characteristics are also included. The design has been produced in small quantities for use in our Design Accelerator Kits. * Downloadable from www.powerint.com www.powerint.com Design Idea DI-77 ® TinySwitch-II 3 W Adapter: <200 mW No-Load Consumption Application Device Power Output Input Voltage Output Voltage Topology Adapter TNY263P 3W 85-265 VAC 9 V / 330 mA Flyback (a similarly rated linear transformer adapter will typically consume approximately 1 W under no-load). This low no-load consumption is the result of the inherent cycle skipping feature of the TinySwitch-II and careful transformer design. Design Highlights • • • • • • Replaces a linear transformer based power supply at the same or lower cost, but with much higher performance <200 mW no-load consumption (at 115/230 VAC) Meets CISPR 22-B with >15 dB margin, w/o Y capacitor Low cost, low component count solution: only 24 parts! TinySwitch-II On/Off regulation scheme produces ±5% output regulation over temperature with a 2% Zener Does not require a transformer bias winding Key Design Points • Operation • This TinySwitch-II based flyback converter produces an isolated 3 W, 9 VDC output from an 85 VAC to 265 VAC input. Fusible resistor RF1 gives short circuit fault protection and limits startup inrush current. Inductors L1 and L2 and capacitors C1 and C2 form a low-cost pi ( ) filter that attenuates conducted EMI. In addition, the internal frequency jitter of the TinySwitch-II, the use of shield windings, an output RC snubber, and a primary-side RCD clamp makes the circuit meet CISPR-22 Class B conducted EMI limits without a Y capacitor, resulting in a very low value of AC leakage current (<300 A). • • • Minimize secondary-side power consumption. Zener diode VR1 receives its bias current from the opto-LED in U2. Using a low current device minimizes consumption while providing an output voltage tolerance of ±5%. A TL431 can be used for tighter output voltage accuracy. Minimize clamp losses: design the transformer to have a low reflected voltage (VOR). In this case, VOR was set to 90 V. Minimize leakage inductance: select wire gauge sizes that completely fill each winding layer of the transformer. Minimize intra-winding capacitance and no-load consumption: put a layer of tape between each primary winding layer. Use >200 k resistor in the RCD clamp to further reduce power losses if the following two conditions are met: 1) the EMI performance is not compromised, and 2) there is enough drain voltage (BVDSS) margin for the internal MOSFET. The key performance characteristic of this circuit is the extremely low no-load power consumption of <200 mW R2 16 Ω L2 Bead R1 200 kΩ 1/2 W L D1 1N4007 D2 1N4007 10 85 - 265 VAC R3 200 Ω C2 4.7 µF 400 V D D4 1N4007 S L1 1.0 mH C6 100 µF 25 V RTN VR1 BZX79-B8V2 TinySwitch-II U1 TNY263P EN U2 PC817A BP D3 1N4007 C5 330 µF 16 V 8 T1 EE16 Lp = 1.6 mH D5 1N4007G N 9 V, 330 mA D6 11DQ06 3 C1 4.7 µF 400 V L3 Bead NC NC 1 C3 1 nF 1 kV RF1 8.2 Ω 1.0 W C7 1 µF 50 V C4 0.1 µF 50 V PI-3877-052004 Figure 1. TinySwitch-II 3.0 W Adapter. www.powerint.com DI-77 TRANSFORMER PARAMETERS TDK PC40 EE16, AL = 190 nH/T EE16 Horizontal 10 pin Winding Details Core Cancellation: 26T, 2 x 36 AWG Primary: 46T + 46T, 35 AWG Shield: 8T, 2 x 26 AWG Secondary: 10T, T.I.W. 24 AWG Winding Order (pin numbers) Core Cancellation (1-NC), 2 x Tape, Primary (3-1), Tape, Shield (2-NC), 2 x Tape, Secondary (10-8) Primary Inductance 1.60 mH ±10% Primary Resonant Frequency 600 kHz (minimum) Leakage Inductance 50 H (maximum) dBµV 30 20 10 0 7.0 50 100 150 200 250 300 350 Figure 3. Load Regulation–CV Characteristics. Quasi Peak 40 7.5 Output Current (mA) Average 300 PI-3879-051204 PI-3880-051204 AV 8.0 0 70 50 85 VAC 265 VAC 8.5 6 80 QP 9.0 6.5 Table 1. Transformer Construction Information. 60 Output Voltage (VDC) Bobbin 9.5 Power Consumption (mW) Core Material PI-3878-051204 10.0 2 250 200 150 100 50 -10 -20 0.15 0 1.0 10.0 80 -100.0 MHz Figure 2. Conducted EMI, Full-Load, 230 VAC, Power Return Connected to "Artificial Hand" of LISN. 130 180 230 280 Input Voltage (VAC) Figure 4. No-Load Input Power Variation with Input Voltage. For the latest updates, visit our Web site: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. 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. PI Expert and DPA-Switch are trademarks of Power Integrations. ©Copyright 2004, Power Integrations. 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