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Design Example Report
Title Specification Application Author Document Number Date Revision 7.3 W Dual Output Non-Isolated Power Supply using TNY266P Input: 90 - 265 VAC Output: 5V / 500mA, 24V / 200mA Cook Top Control Power Integrations Applications Department DER-110 October 26, 2005 1.0
Summary and Features * * * * * * Compact 1.5" X 2" X 1" PCB footprint Total output power 6.0 W with TNY266P and EE16 core Typical Efficiency 75 % Good cross regulation using low-cost zener Meets EN55022 class B conducted EMI test without Y1 safety capacitor No Optocoupler used in the feedback loop
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-110
Dual Output Non-Isolated Power Supply
October 26, 2005
Table Of Contents
Introduction.................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic...................................................................................................................5 PCB Layout ................................................................................................................6 Bill Of Materials...........................................................................................................7 Transformer Specification...........................................................................................8 6.1 Electrical Diagram ...............................................................................................8 6.2 Electrical Specifications.......................................................................................8 6.3 Materials ..............................................................................................................8 6.4 Transformer Build Diagram .................................................................................9 6.5 Transformer Construction....................................................................................9 7 Transformer Spreadsheets .......................................................................................10 8 Performance Data.....................................................................................................13 8.1 Efficiency ...........................................................................................................13 8.2 No-load Input Power..........................................................................................14 8.3 Regulation .........................................................................................................15 8.3.1 Load ...........................................................................................................15 8.3.2 Line ............................................................................................................16 9 Waveforms ...............................................................................................................17 9.1 Drain Voltage and Current, Normal Operation...................................................17 9.2 Output Voltage Start-up Profile..........................................................................17 9.3 Drain Voltage and Current Start-up Profile ........................................................18 9.4 Load Transient Response (50% to 100% Load Step)........................................18 9.5 Output Ripple Measurements ............................................................................19 9.5.1 Ripple Measurement Technique.................................................................19 9.5.2 Measurement Results ................................................................................20 10 Conducted EMI .....................................................................................................21 11 Revision History ....................................................................................................22 1 2 3 4 5 6
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 isolated source to provide power 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.
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Page 2 of 23
DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
1 Introduction
This document is an engineering report describing a dual output non-isolated power supply utilizing a TNY266P. This power supply is intended as a power supply for a cooktop control module. The document contains the power supply specification, schematic, bill-of-materials, transformer documentation, printed circuit layout, and performance data.
Figure 1 - Populated Circuit Board Photograph
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
2 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 Power Efficiency Environmental Conducted EMI Safety Surge
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Symbol VIN fLINE
Min 90 47
Typ
Max 265 64 0.7
Units VAC Hz W V mV mA V mV mA W %
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 VOUT1 VRIPPLE1 IOUT1 POUT
5 50 500 24 200 200 7.3 80
5% 20 MHz bandwidth
15% 20 MHz bandwidth
Measured at POUT (7.3 W), 25 oC
4
kV
Surge Ambient Temperature TAMB
3 0 70
kV
o
1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: 12 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level
C
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
3 Schematic
Figure 2 - Schematic
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
4 PCB Layout
Figure 3 - Printed Circuit Layout
Page 6 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
5 Bill Of Materials
Item QTY Ref. Des. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 C1 C2 C3 C4 C5 C7 C6 C8 D1 D2 D3 D4 L1 L2 Q1 R1 R2 R3 R4 R5 RF1 T1 U1 VR1 Mfg Mfg Part Number KMX400VB22RM16X20LL KZE35VB331MJ16LL LXZ10VB102MH20LL 22 uF, 400 V, Electrolytic, Low ESR, 901 mOhm, (16 x 20) United Chemi-Con 330 uF, 35 V, Electrolytic, Very Low ESR, 38 mOhm, (10 x 16) United Chemi-Con 1000 uF, 10 V, Electrolytic, Low ESR, 80 mOhm, (8 x 20) United Chemi-Con 100 nF, 50 V, Ceramic, X7R, 0805 2.2 nF, 1 kV, Disc Ceramic 100 uF, 10 V, Electrolytic, Low ESR, 500 mOhm, (5 x 11.5) 1000 V, 1 A, Rectifier, Glass Passivated, DO-213AA (MELF) 400 V, 1 A, Rectifier, Glass Passivated 40 V, 1 A, Schottky, DO-214AC 200 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC 1000 uH, 0.29 A 3.3 uH, 2.66 A NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 75 R, 5%, 1/8 W, Metal Film, 0805 200 k, 5%, 1 W, Metal Oxide 100 R, 5%, 1/8 W, Metal Film, 0805 330 R, 5%, 1/8 W, Metal Film, 0805 10 R, 5%, 1/8 W, Metal Film, 0805 8.2 R, 2.5 W, Fusible/Flame Proof Wire Wound Bobbin, EE16, Vertical, 8 pins TinySwitch-II, TNY266P, DIP-8B 4.3 V, 5%, 500 mW, DO-213AA (MELF)
Panasonic ECU-V1H221KBN NIC Components Corp NCD222K1KVY5F United Chemi-Con Diodes Inc Diodes Inc Vishay Vishay Tokin Toko Vishay Panasonic Yageo Panasonic Panasonic Panasonic Vitrohm Bu Chang Ind Co Ltd Power Integrations Diodes Inc LXZ10VB101ME11LL DL4007 S1GB-13 SS14 ES1C SBC4-102-291 822LY-3R3M MMBT3904 ERJ-6GEYJ750V RSF100JB-200K ERJ-6GEYJ101V ERJ-6GEYJ331V ERJ-6GEYJ100V CRF253-4 5T 8R2 TNY266P ZMM5229B-7
Page 7 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
6 Transformer Specification
6.1 Electrical Diagram
Figure 4 - Transformer Electrical Diagram
6.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-4 to Pins 5-10 Pins 1-4, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-4, all other windings open Pins 1-4, with Pins 5-10 shorted, measured at 100 kHz, 0.4 VRMS 200 VAC 1570 H, 0/+20% 800 kHz (Min.) 60 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
6.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] Description Core: EE16 PC40 Al = 124nH/T Bobbin: 10-pin Vertical Magnet Wire: #34 Heavy Build Magnet Wire: #33 Heavy Build Magnet Wire: #27 Heavy Build Tape, 3M Varnish
2
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
6.4
Transformer Build Diagram
Figure 5 - Transformer Build Diagram
6.5
Transformer Construction
Core Shield Basic Insulation Primary Basic Insulation Secondary Winding Secondary Winding Outer Wrap Final Assembly Start at pin 6 and wind 20 turns of bifilar wound #34. Do not connect finish end of this winding. Apply three layers of tape for basic insulation. Start on pin 4, wind 108 turns of #33 in three layers. Apply one layer of tape between each adjacent winding layer. Apply two layers of tape for basic insulation. Start on pin 5, wind 6 turns of trifilar #27 in one layer. Finish on pin 6. Start on pin 8, wind 21 turns of #27 in one layer. Finish on pin 5. Wrap windings with 3 layers of tape. Assemble and secure core halves. Dip varnish, do not impregnate (item [7]).
Page 9 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
7 Transformer Spreadsheets
ACDC_TNYII_020105; Rev.2.4; Copyright Power Integrations Inc. 2005 INPUT INFO
ACDC_TNYII_020105_Rev2-4.xls; TinySwitch-II Continuous/Discontinuous Flyback Transformer OUTPUT UNIT Design Spreadsheet
ENTER APPLICATI ON VARIABLE S
VACMIN VACMAX fL VO PO n Z tC CIN 20 85 265 50 5 7.3 0.7 0.5
mSec Volts Volts Hertz Volts Watts
Customer
Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor
3 onds Bridge Rectifier Conduction Time Estimate
uFara Input Filter Capacitor ds
ENTER TinySwitch-II VARIABLES
TinySwitch-II Chosen Device
tny26 6
Univer 115 Doubled/230V sal
ILIMITMIN ILIMITMAX fS fSmin fSmax VOR VDS VD KP
Power TNY266 Out 9.5W 0.325 Amps 0.375 Amps 132000 Hertz 120000 Hertz 144000 Hertz 99 0.5
15W TinySwitch-II Minimum Current Limit TinySwitch-II Maximum Current Limit TinySwitch-II Switching Frequency TinySwitch-II Minimum Switching Frequency (inc. jitter) TinySwitch-II Maximum Switching Frequency (inc. jitter) Volts Reflected Output Voltage 10 Volts TinySwitch-II on-state Drain to Source Voltage Volts Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.6ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type Core Bobbin
EE16 EE16 EE16_B OBBIN
P/N:
PC40EE16-Z
AE LE AL
P/N: BE-16-118CPH 0.192 cm^2 Core Effective Cross Sectional Area 3.5 cm Core Effective Path Length 1140 nH/T^ Ungapped Core Effective Inductance
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Page 10 of 23
DER-110
Dual Output Non-Isolated Power Supply
2
October 26, 2005
BW M L NS 0 3 6
8.5 mm
mm
Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns
DC INPUT VOLTAGE PARAMETERS
VMIN VMAX 85 Volts Minimum DC Input Voltage 375 Volts Maximum DC Input Voltage
CURRENT WAVEFORM SHAPE PARAMETERS
DMAX IAVG IP IR IRMS 0.57 0.12 Amps 0.33 Amps 0.22 Amps 0.17 Amps Maximum Duty Cycle Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP NP ALG BM BAC ur LG BWE OD INS DIA AWG CM CMA 1570 uH 108
nH/T^
Primary Inductance Primary Winding Number of Turns
135 2 Gapped Core Effective Inductance 2840 Gauss Maximum Flux Density, (BP<3100) AC Flux Density for Core Loss Curves (0.5 X Peak to 824 Gauss Peak) 1654 Relative Permeability of Ungapped Core 0.16 mm Gap Length (Lg > 0.1 mm) 25.5 mm Effective Bobbin Width 0.24 mm Maximum Primary Wire Diameter including insulation 0.05 mm Estimated Total Insulation Thickness (= 2 * film thickness) 0.19 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard 33 AWG AWG value) 51 Cmils Bare conductor effective area in circular mils
Cmils/
299 Amp
Primary Winding Current Capacity (200 < CMA < 500)
TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters
ISP ISRMS IO IRIPPLE CMS AWGS 5.85 Amps 2.66 Amps 1.46 Amps 2.22 Amps 531 Cmils 22 AWG Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger
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Page 11 of 23
DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
DIAS ODS INSS
0.65 mm 1.42 mm 0.39 mm
standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness
VOLTAGE STRESS PARAMETERS
VDRAIN PIVS Maximum Drain Voltage Estimate (Includes Effect of 603 Volts Leakage Inductance) 26 Volts Output Rectifier Maximum Peak Inverse Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output
VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 CMS1 AWGS1 DIAS1 ODS1 5 0.5 0.5 5 Volts 0.500 Amps 2.50 Watts 0.5 Volts 6.00 0.910 Amps 0.76 Amps 26 Volts Output Voltage (if unused, defaults to single output design) Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage
182 Cmils Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG 27 AWG value) 0.36 mm Minimum Bare Conductor Diameter 1.42 mm Maximum Outside Diameter for Triple Insulated Wire
2nd output
VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 CMS2 AWGS2 DIAS2 ODS2 24 0.2 0.6 Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop 26.84 Output Winding Number of Turns 0.364 Amps Output Winding RMS Current 0.30 Amps Output Capacitor RMS Ripple Current 117 Volts Output Rectifier Maximum Peak Inverse Voltage
Volts Amps 4.80 Watts Volts
73 Cmils Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG 31 AWG value) 0.23 mm Minimum Bare Conductor Diameter 0.32 mm Maximum Outside Diameter for Triple Insulated Wire
Page 12 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
8 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 8.1 Efficiency
Figure 6 - Efficiency at Full Load vs. Input Voltage, Room Temperature, 60 Hz.
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DER-110 8.2
Dual Output Non-Isolated Power Supply
October 26, 2005
No-load Input Power
Figure 7 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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DER-110 8.3 Regulation
Dual Output Non-Isolated Power Supply
October 26, 2005
8.3.1 Load
Figure 8 - Load Regulation @ 120VAC Input, Room Temperature
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DER-110 8.3.2 Line
Dual Output Non-Isolated Power Supply
October 26, 2005
Figure 9 - Line Regulation, Room Temperature, Full Load
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
9
9.1
Waveforms
Drain Voltage and Current, Normal Operation
Figure 10 - 85 VAC, Full Load. Upper: IDRAIN, 0.5 A / div Lower: VDRAIN, 100 V, 2 s / div
Figure 11 - 265 VAC, Full Load Upper: IDRAIN, 0.5 A / div Lower: VDRAIN, 200 V / div
9.2
Output Voltage Start-up Profile
Figure 12 - Start-up Profile, 90 VAC 5 ms / div.
Figure 13 - Start-up Profile, 265 VAC 5 ms / div.
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DER-110 9.3
Dual Output Non-Isolated Power Supply
October 26, 2005
Drain Voltage and Current Start-up Profile
Figure 14 - 85 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 100 V & 1 ms / div.
Figure 15 - 265 VAC Input and Maximum Load. Upper: IDRAIN, 0.5 A / div. Lower: VDRAIN, 200 V & 1 ms / div.
9.4 Load Transient Response (50% to 100% Load Step) In the figures shown below, signal averaging was used to better enable viewing the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response.
Figure 16 - Transient Response, 90 VAC, 75-10075% Load Step. Top: Load Current, 0.2 A/div. Bottom: Output Voltage 50 mV, 5ms / div.
Figure 17 - Transient Response, 265 VAC, 75-10075% Load Step Upper: Load Current, 0.2 A/ div. Bottom: Output Voltage 50 mV, 5 ms / div.
Page 18 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
9.5
Output Ripple Measurements
9.5.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 18 and Figure 19. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 18 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 19 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
Page 19 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
9.5.2 Measurement Results
Figure 20 - Ripple, 90 VAC, Full Load. 50us
Figure 21 - Ripple, 265 VAC, Full Load. 50us
Page 20 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
10 Conducted EMI
A conducted EMI scan of the prototype was taken to determine the effectiveness of the input pi-filter and transformer ESHIELD(R) construction. The following plots show the peak performance of the converter against quasi-peak (QP) and average (AVG) limits of EN55022 Class B. Both scans were taken at 120VAC/60Hz input with maximum load applied to the outputs. Since the peak scans are below the average limits, it is expected that the QP and Average scans would have greater than 10db of margin below the limits.
Figure 22 - Conducted EMI (LINE), Maximum Load, 120 VAC, 60 Hz, and EN55022 B Limits
Figure 23 - Conducted EMI (Neutral), Maximum Load, 120 VAC, 60 Hz, and EN55022 B Limits
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
11 Revision History
Date 10-26-05 Author RSP Revision 1.0 Description & changes Initial Release Reviewed KM/JC/VC
Page 22 of 23
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DER-110
Dual Output Non-Isolated Power Supply
October 26, 2005
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. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NONINFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) 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 grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, EcoSmart, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)Copyright 2005 Power Integrations, Inc.
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