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Design Example Report
Title Specification Application Author Document Number Date Revision 13.1 W AC-DC Flyback Converter Using TNY268P Input: 90 - 264 VAC Output: 5.25 V / 2.5 A Adapter Power Integrations Applications Department DER-121 November 3, 2005 1.0
Summary and Features * * * * * * * * Universal Input 90 VAC to 264 VAC Low Cost, Low Parts Count Minimum No Load Power Consumption <0.3 W at 264 VAC Meets CISPR22B EMI with Margin Efficiency >70% minimum. Meet CEC efficiency requirement with 5.25V2.5A. Meets +/-6KV-200A Lightning Surge. Cost reduced circuit does not require TVS
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-121
13.1 W adapter - TNY268
November 3, 2005
Table Of Contents
Introduction .................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic ...................................................................................................................5 Circuit Description.......................................................................................................6 4.1 Input Rectification and EMI Filtering ....................................................................6 4.2 TOPSwitch Primary .............................................................................................6 4.3 Output Rectification .............................................................................................6 4.4 Output Feedback .................................................................................................6 5 PCB Layout.................................................................................................................7 6 Bill Of Materials...........................................................................................................8 7 Transformer Specification ...........................................................................................9 7.1 Electrical Diagram................................................................................................9 7.2 Electrical Specifications .......................................................................................9 7.3 Materials ..............................................................................................................9 7.4 Transformer Build Diagram................................................................................10 7.5 Transformer Construction ..................................................................................10 8 Transformer Spreadsheets .......................................................................................11 9 Design Results..........................................................................................................11 9.1 Device Variables................................................................................................11 10 Performance Data .................................................................................................14 10.1 Efficiency ...........................................................................................................14 10.2 No-load Input Power ..........................................................................................14 10.3 Regulation .........................................................................................................15 10.4 CEC Efficiency...................................................................................................16 11 Waveforms ............................................................................................................17 11.1 Drain Voltage and Current, Normal Operation...................................................17 11.2 Output Voltage Start-up Profile ..........................................................................17 11.3 Drain Voltage and Current Start-up Profile ........................................................18 11.4 Load Transient Response (50% to 100% Load Step)........................................18 11.5 Output Ripple Measurements ............................................................................19 12 Conducted EMI .....................................................................................................22 13 Revision History ....................................................................................................23 1 2 3 4
Important Note: This board is designed to be non-isolated. However the outputs are high voltage so please take the necessary safety precautions. 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 24
DER-121
13.1 W adapter - TNY268
November 3, 2005
1 Introduction
This document is an engineering report describing an Adapter power supply utilizing a TNY268P. This power supply is intended as a general purpose evaluation platform for TNY268P. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
TOP
Bottom
Figure 1 - Populated Circuit Board Photograph.
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DER-121
13.1 W adapter - TNY268
November 3, 2005
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (264 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Efficiency CEC Efficiency (115 VAC and 230 VAC) Environmental Conducted EMI Safety Surge Ambient Temperature TAMB Symbol VIN fLINE Min 90 47 Typ Max 264 63 0.3 5.5 50 2.5 13.1 70 72.2 Units VAC Hz W V mV A W % %
Measured at POUT (13.1 W), 25 C Avg. Eff. At 25%, 50%, 75% and 100% load
o
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 POUT Avg.
5 0
5.25
5% 20 MHz bandwidth
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
6 0 40
kV
o
100 kHz ring wave, 200 A short circuit current, differential and common mode Free convection, sea level
C
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DER-121
13.1 W adapter - TNY268
November 3, 2005
3 Schematic
Figure 2 - Schematic.
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DER-121
13.1 W adapter - TNY268
November 3, 2005
4 Circuit Description
A Flyback converter is used to obtain 5.25 V / 2.5 A output from 90-264 VAC input. Using technical skill of core cancellation and balance shield windings reduce EMI noise. 4.1 Input Rectification and EMI Filtering Fuse F1 protects the charger against any fault condition, and input current exceeds 1 A. Diodes D1, D2, D3, and D4 form Full-bridge rectifier, and rectify the AC voltage into DC voltage and charge the capacitors C1 and C2. L1, L2, C1, and C2 form - filter and attenuate EMI noise. Here, C1 and C2 act as both storage capacitors and part of EMI filter, which reduces the total cost. 4.2 TOPSwitch Primary This design uses RCD (C4, D5, R3, and R4) clamping across primary winding to limit the drain voltage below 700V, when the Mosfet inside U1 turns OFF. The capacitor C5 connected to BP (by-pass) pin of U1 stores energy and provide power for the internal circuit of U1 and also to turn ON the U1's Mosfet, during power-up and steady state operation. The opto-coupler transistor pulls down enable (EN) pin of U1. TinySwitch-II keeps on switching as long as the pull down current < 240 A. U1 will stop switching if the pull down current exceeds 240 A. 4.3 Output Rectification
When U1 Mosfet is turned ON, current flows through transformer primary and stores energy. When U1 is ON, output diode D6 is OFF. When the U1 Mosfet is OFF, D6 is forward biased, and the stored energy is transferred to the secondary and stores in C6, C8 and C9. The snubber C7 and R5 across output diode D6 and a bead core in series with output diode D6 will improve EMI. 4.4 Output Feedback Resistors R8, R9 divide down the supply output voltage and apply it to the reference pin of error amplifier U3. Shunt regulator U3 drives optocoupler U2 through resistor R6 to provide feedback information to the U1 EN pin. Capacitor C10 drive to the optocoupler during supply startup to reduce output voltage overshoot. C11 plays a role in compensating of the power supply feedback loop.
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DER-121
13.1 W adapter - TNY268
November 3, 2005
5 PCB Layout
TOP
BOTTOM
Figure 3 - Printed Circuit Layout.
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DER-121
13.1 W adapter - TNY268
November 3, 2005
6 Bill Of Materials
Item Qty Part Reference 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 1 1 1 1 2 1 1 1 1 1 4 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 C1 C2 C3 C4 C5 C6 C8 C7 C9 C10 C11 C12 D1 D2 D3 D4 D5 D6 F1 L1 L2 L3 L4 R1 R2 R3 R4 R5 R6 R7 R8 R9 RV1 T1 U1 U2 U3 Value 22 uF 33 uF 10 nF 2.2 nF 100 nF 2.2 nF 470 uF 2.2 uF 10 nF 470 pF 1N4007 Description 22 uF, 400 V, Electrolytic, Low ESR, 2.9 Ohms, (12 x 20) 33 uF, 400 V, Electrolytic, Low ESR, 901 mOhm, (16 x 20) 10 nF, 1 kV, Disc Ceramic 2.2 nF, 1 kV, Disc Ceramic 100 nF, 50 V, Ceramic 2.2 nF, 100 V, Ceramic, COG 470 uF, 10 V, Electrolytic, Gen. Purpose, (8 x 12) 2.2 uF, 50 V, Electrolytic, (5 x 11) 10 nF, 50 V, Ceramic 470 pF, 250 Vac, Thru Hole, Ceramic Y-Capacitor 1000 V, 1 A, Rectifier, DO-41
1000 uF 1000 uF, 10 V, Electrolytic, Very Low ESR, 41 mOhm, (8 x 20)
1N4007GP 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 MBR1040 40 V, 10 A, Schottky, TO-220AC 250V,1 A 1 A, 250V, Fast, Picofuse, Axial 2 mH 3.3 uH 10 k 100 k 200 10 47 1k 10 k 11k 275 Vac EI22 2mH, 0.15A 3.3 uH, 2.66 A 10 k, 5%, 1/4 W, Carbon Film 100 k, 5%, 1/2 W, Carbon Film 200 R, 5%, 1/2 W, Carbon Film 10 R, 5%, 1/2 W, Carbon Film 47 R, 5%, 1/8 W, Carbon Film 1 k, 5%, 1/8 W, Carbon Film 10 k, 1%, 1/8 W, Carbon Film 11 k, 1%, 1/8 W, Carbon Film 275 V, 45 J, 10 mm, RADIAL Transformer, EI22 10pins Bead Core 3.5 mm x 10 mm, 213 Ohms at 10 MHz, 24 AWG hole, Ferrite Bead
TNY268P TinySwitch-II, TNY268P, DIP-8B PC817B Opto coupler, 35 V, 4-DIP TL431 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92
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DER-121
13.1 W adapter - TNY268
November 3, 2005
7 Transformer Specification
7.1 Electrical Diagram
T1
1
N2 0.23mm x1 64T / 2L
EI22
8
3
N3 0.25mm x4 7T / 1L
N4 0.45mm x3 4T / 1L
NC 1 10
N1 0.28mm x1 27T / 1L
NC
Figure 4 - Transformer Electrical Diagram.
7.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-5 to Pins 6-10 Pins 1-3, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-3, all other windings open Pin 1-3 with Pin 8-10 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 1.32mH, -/+5% 1MHz (Min.) 30 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description Core: PC40 EI22 Bobbin: EI 22, 10 Pin Magnet Wire: 0.28mm heavy Nyleaze Magnet Wire: 0.23mm heavy Nyleaze Magnet Wire: 0.25mm heavy Nyleaze Triple Insulated Wire: 0.45mm Tape: 3M 1298 Polyester Film (yellow) 15mm, 0.26m Thick. Tape: 3M 1298 Polyester Film (yellow) 10mm, 0.25mm Thick. Varnish
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DER-121
13.1 W adapter - TNY268
November 3, 2005
7.4
Transformer Build Diagram
-> 3L Tape
Pin10 Pin8 NC Pin1
N4/0.45mm*3 4T/1L
-> 2L Tape
N3/0.25mm*4 7T/1L
-> 3L Tape
Pin1 N2/0.23mm*1 64T/2L Pin3
-> 2L Tape
N1/0.28mm*1 27T/1L NC Pin1
UP
Figure 5 - Transformer Build Diagram.
Bottom
7.5
Transformer Construction
Core Canceling Winding Insulation Primary Layer Insulation Balance Shield Winding Insulation Secondary Winding Insulation Final Assembly Start at Pin 1.wind 27 turns of item [3] from right to left. Finish at Pin NC. 2 Layers of tape [7] for insulation Start at Pin 3. Wind 64 turns / 2Layers of item [4]. Wind 1'st layer from left to right; and add 1 layer of tape [7] for insulation; and then wind 2'nd layer from right to left. Finish at Pin 1. 3 Layers of tape [7] for insulation Start at Pin 1. Wind quad-filar 7 turns of item [5] from right to left. Finish at NC. 2 Layers of tape [7] for insulation. Start at Pin 8 Wind tri-filar 4 turns of item [6] from right to left. Finish at Pin 10. 3 Layers of tape [7] for insulation. Assemble and secure core halves. Put 3 Layers of item [8]. Impregnate uniformly with dip varnish [9] and bake.
Page 10 of 24
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DER-121
13.1 W adapter - TNY268
November 3, 2005
8
Transformer Spreadsheets
Design Warning (No Optimization)
EI22 Vout 1: 5.00 V, 2.50 A CLAMP Vin 90-265 V EMI AC & Rectifier TNY268P D EN BP S Feedback Cin From Vout 1 EN/UV 64T 4T RTN
9
Design Results
Var VACMIN VACMAX FL TC Z N Value 90 265 50 2.59 0.56 70.0 % Output 1. (main) Units Volts Volts Hertz mSeconds Description Min Input AC Voltage. Max Input AC Voltage Line Frequency Diode Conduction Time Loss Allocation Factor Efficiency Estimate
Power Supply Input
Power Supply Outputs
Var VOx IOx Value Output 1. (main) 5.00 2.50 Units Volts Amps Description Output Voltage Output Current
9.1
Device Variables
Var Device PO VDRAIN VDS FSNOM FSMIN FSMAX Value TNY268P 12.5 580 3.04 132000 120000 144000 Output 1. (main) Units Watts Volts Volts Hertz Hertz Hertz Description PI Device Name Total Output Power Maximum Drain Voltage Drain to Source Voltage TinySwitch-II Switching Frequency Minimum Switching Frequency Maximum Switching Frequency Continuous/Discontinuous Operating Ratio. See Errors, Warnings, Information section for detail
KRPKDP
0.53
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DER-121
ILIMITMIN ILIMITMAX IRMS DMAX 0.51 0.59 0.27 0.46
13.1 W adapter - TNY268
Amps Amps Amps
November 3, 2005
Current Limit Minimum Current Limit Maximum Primary RMS Current Maximum Duty Cycle
Power Supply Components Selection
Var VBRIDGE IAVG CIN VMIN VMAX VCLO PZ Value 600 0.17 55.0 106.7 374.8 130 1.5 Output 1. (main) Units Volts Amps uFarads Volts Volts Volts Watts Description Diode Bridge Voltage Rating Average Diode Bridge Current Input Capacitance Minimum DC Input Voltage Maximum DC Input Voltage Clamp Zener Voltage Primary Zener Clamp Loss
Power Supply Output Parameters
Var VDx Value Output 1. (main) 0.50 Units Volts Description Output Winding Diode Forward Voltage Drop Output Rectifier Maximum Peak Inverse Voltage Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current
PIVSx ISPx ISRMSx IRIPPLEx
28 7.88 4.35 3.56
Volts Amps Amps Amps
Transformer Construction Parameters
Var Core/Bobbin Core Manuf. Bobbin Manuf LPmin NP AWG CMA VOR BW M L AE ALG 9.1.1 Value EI22 Generic 1263 64.0 32 238 88.00 8.45 0.0 2.00 42.00 308 mm^2 nH/T^2 AWG Cmils/A Volts mm mm uHenries Output 1. (main) Units Description Core Type Core Manufacturer Bobbin Manufacturer Minimum Primary Inductance Primary Number of Turns Primary Wire Gauge Primary Winding Current Capacity Reflected Output Voltage Bobbin Winding Width Safety Margin Width Primary Number of Layers Core Cross Sectional Area Gapped Core Effective Inductance
Generic
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DER-121
BM BAC LG LL LSEC 2863 659 0.149 25.3 20
13.1 W adapter - TNY268
Gauss Gauss mm uHenries nHenries
November 3, 2005
Maximum Flux Density AC Flux Density for Core Loss Estimated Gap Length Primary Leakage Inductance Secondary Trace Inductance
Secondary Parameters
Var NSx Rounded Down NSx Value Output 1. (main) 4.0 Units Description Secondary Number of Turns Rounded to Integer Secondary Number of Turns Auxiliary Output Voltage for Rounded down to Integer Secondary Number of Turns Rounded to Next Integer Secondary Number of Turns Auxiliary Output Voltage for Rounded up to Next Integer Secondary Number of Turns Secondary Wire Gauge Range. See Errors, Warnings, Information section for detail
Rounded Down Vox
Volts
Rounded Up NSx
Rounded Up Vox
Volts
AWGSx Range
17 - 21
AWG
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DER-121
13.1 W adapter - TNY268
November 3, 2005
10 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 10.1 Efficiency
Eff vs. Input Voltage
77 76 75 Eff (%) 74 73 72 71 70 90 115 140 160 Vin (Vac) 180 230 264
Figure 6 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
10.2 No-load Input Power
Zero Load Input Power vs. Input Voltage
300 250 Eff (%) 200 150 100 50 0 90 115 140 160 Vin (Vac) 180 230 264
Figure 7 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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DER-121 10.3 Regulation
13.1 W adapter - TNY268
November 3, 2005
10.3.1 Load (Vin: 115 VAC) Load Regulation vs. Voltage Output
5.3 5.29 5.28 5.27 5.26 5.25 5.24 5.23 5.22 5.21 5.2 0 0.3 0.7 1 1.3 Vin (Vac) 1.7 2 2.3 2.5
Eff (%)
Figure 8 - Load Regulation, Room Temperature.
10.3.2 Line (Load: 2.5A) Line Regulation vs. Voltage Output
5.28 5.275 5.27 Eff (%) 5.265 5.26 5.255 5.25 90 115 140 160 Vin (Vac) 180 230 264
Figure 9 - Line Regulation, Room Temperature, Full Load.
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Page 15 of 24
DER-121 10.4 CEC Efficiency
13.1 W adapter - TNY268
November 3, 2005
CEC Specification: Eff. > 0.09 x ln (Po)+0.49 = 72.17 % @ 115 VAC and 230 VAC. Load (%) Vin (VAC) 115 230 25% (0.625 A) 72.3% 73.5% 50% (1.25 A) 73.3% 75.8% 75% (1.875 A) 74.3% 74.8% 100% (2.5 A) 73.2% 74.63%
Avg. Eff (%) 73.2% 74.625%
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DER-121
13.1 W adapter - TNY268
November 3, 2005
11 Waveforms
11.1 Drain Voltage and Current, Normal Operation
Figure 10 - 90 VAC, Full Load. Lower: IDRAIN, 0.2 A / div Upper: VDRAIN, 100 V, 10 s / div
Figure 11 - 264 VAC, Full Load Lower: IDRAIN, 0.2 A / div Upper: VDRAIN, 200 V / div, 10 s / div
11.2 Output Voltage Start-up Profile
Figure 12 - Start-up Profile, 90 VAC, Full load 1 V/ div, 10 ms / div.
Figure 13 - Start-up Profile, 264 VAC, Full load 1 V/ div, 10 ms / div.
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DER-121
13.1 W adapter - TNY268
November 3, 2005
11.3 Drain Voltage and Current Start-up Profile
Figure 14 - 90 VAC Input and Maximum Load. Lower: IDRAIN, 0.2 A / div. Upper: VDRAIN, 100 V & 1 ms / div.
Figure 15 - 264 VAC Input and Maximum Load. Lower: IDRAIN, 0.2 A / div. Upper: VDRAIN, 200 V & 1 ms / div.
11.4 Load Transient Response (50% to 100% Load Step)
Figure 16 - Transient Response, 90 VAC, 50-10050% Load Step. Upper: Load Current, 1 A/div. Lower: Output Voltage 100 mV/ div, 5 ms / div.
Figure 17 - Transient Response, 264 VAC, 50-10050% Load Step Upper: Load Current, 1 A/ div. Lower: Output Voltage 100 mV/ div, 5 ms / div.
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DER-121
13.1 W adapter - TNY268
November 3, 2005
11.5 Output Ripple Measurements
11.5.1 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).
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DER-121
13.1 W adapter - TNY268
November 3, 2005
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DER-121
13.1 W adapter - TNY268
November 3, 2005
11.5.2 Measurement Results
Figure 20 - 5.25V Ripple, 90 VAC, Full Load. 20 ms/ div, 20 mV / div
Figure 21 - 5.25V Ripple, 115 VAC, Full Load. 20 ms/ div, 20 mV / div
Figure 22 - 5.25V Ripple, 230 VAC, Full Load. 20 ms/ div, 20 mV / div
Figure 23 - 5.25V Ripple, 264 VAC, Full Load. 20 ms/ div, 20 mV / div
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DER-121
13.1 W adapter - TNY268
November 3, 2005
12 Conducted EMI
115 VAC
Att
dBV 100
10
dB
RBW MT PREAMP
9 kHz 50 ms OFF 10 MHz
1
MHz
OVLD 1 QP * MAXH 2 AV * MAXH
90
80
70
TDS
EN55022Q
60 PRN
EN55022A
50
40
30
20
10
0
150
kHz
30
MHz
Date:
9.MAY.2005
09:20:09
Figure 24 - Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits
220 VAC
Att
dBV 100
10
dB
RBW MT PREAMP
9 kHz 50 ms OFF 10 MHz
1
MHz
OVLD 1 QP * MAXH 2 AV * MAXH
90
80
70
TDS
EN55022Q
60 PRN
EN55022A
50
40
30
20
10
0
150
kHz
30
MHz
Date:
9.MAY.2005
08:58:09
Figure 25 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits
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DER-121
13.1 W adapter - TNY268
November 3, 2005
13 Revision History
Date 11-3-05 Author Ralph Sung Revision 1.0 Description & changes Initial Release Reviewed JC/KM
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DER-121
13.1 W adapter - TNY268
November 3, 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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