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Engineering Prototype Report (EPR-000008) Title
1.2 W, Universal Input, Non-isolated, TNY254 (EP8)
Customer Author Document Number Date Revision
Abstract
Home Appliance Market S.L. EPR-000008 08-May-2001 10
This document presents the specification, schematic & BOM, inductor calculation, test data and wave forms for a low cost, non-isolated, converter for a home appliance application (triac driving).
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-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
Table Of Contents
Introduction...................................................................................................................... 3 Power Supply Specification ............................................................................................. 3 Schematic........................................................................................................................ 4 3.1 Configuration "1" - 2 kV (1.2/50 ms) Surge Withstand ................................................. 4 3.2 Configuration "2" - 6 kV (1.2/50 ms) Surge Withstand ................................................. 5 4 Circuit Description ...........................................................................................................6 5 Layout ............................................................................................................................. 7 6 Bill of Materials ................................................................................................................ 8 6.1 Configuration "1", 2 kV ................................................................................................. 8 6.2 Configuration "2", 6 kV ................................................................................................. 8 7 Inductor ........................................................................................................................... 9 7.1 Calculation ................................................................................................................... 9 7.2 Spreadsheet .............................................................................................................. 10 8.0 Performance Data ......................................................................................................... 11 8.1 Efficiency ................................................................................................................... 11 8.2 Regulation..................................................................................................................12 8.3 Temperature .............................................................................................................. 12 8.4 Waveforms................................................................................................................. 13 8.5 Transient Response................................................................................................... 16 8.6 Surge Voltage Immunity (2 kV and 6 kV, 1.2/50 ms per IEC1000-4-5)....................... 17 Revision History.................................................................................................................... 19 1 2 3
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
1 Introduction
There are three specific requirements for this power supply: 1. To provide power for driving a trial requires that the output power be referenced to the input line (L), with no series impedance, therefore only 1/2 wave rectification is allowed and the switch must be in the return side of the primary switching circuit. EMI filtering, if necessary, has to be implemented at the system level. 2. The unit has to operate at 85 C ambient. 3. The unit has to withstand 2 kV (configuration "1", page 4) and 6 kV (configuration "2", page 5) input surge voltage as defined by IEC 1000-4-5 (1.2/50 ms). The surge protection added to satisfy these requirements reduces the converter efficiency. It would be more beneficial (lower cost, improved efficiency) if the surge protection were implemented at the system (appliance) level.
2
Power Supply Specification
Symbol VAC fLINE VOUT VRIPPLE IOUT Min 85 47 10.8 0 12 80 Typ Max 265 63 13.2 120 100 Units VAC Hz V MV MA Comment
50/60 Hz
The specification below is for the worst case (6 kV configuration "2")
Description Input Input Voltage Input frequency Output Output Voltage Output Ripple Voltage Output Current Load Regulation Line Regulation Power Output Continuous Output power Power supply efficiency Environmental Temperature EMI - conducted Safety Input Surge Voltage Input Surge Voltage
12 V+/-10%* of VOUT @ full load ~200 mA short 0-100% load 85-265 VAC, full load 0-85 C internal ambient** @low line, full load 6" x 6" x 4" enclosure Designed to meet CISPRR 22B (FCCB) Designed to meet IEC950 IEC1000-4-5 IEC1000-4-5
POUT h TAMB
0 50 0
1.2
W %
85
C
Config. "1" Config. "2"
2 6
kV kV
* +/-5% with 2% Zener. **The unit was placed in a 6" x 6" x 4" enclosure inside the temperature chamber.
Page 3 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
3 Schematic
3.1 Configuration "1" - 2 kV (1.2/50 ms) Surge Withstand
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Page 4 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
3.2
Configuration "2" - 6 kV (1.2/50 ms) Surge Withstand
Page 5 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
4 Circuit Description
The circuit is a fail-safe, non-isolated fly-back topology. Fail-safe means that the output is not subjected to high voltage DC if the switch (U1) fails, since the diode D2 blocks the voltage. During the ON time (U1 conducting), L1 is charged up to ILIMIT of the TNY254 (0.25 A type.), from the energy stored in C1. During the OFF time (U1 blocking), the energy stored in L1 is transferred to C3 and the load via D2. The device switching frequency is 44 kHz. The surge protection circuit has to prevent the TinySwitch VDSMAX from exceeding 700 V. The surge protection for configuration "1" (2 kV) and configuration "2" (6 kV) is illustrated in the schematics (pages 4, 5). Configuration "1" relies on the current/energy-limiting resistor R2 to keep the maximum charging voltage of C1 during a +2 kV surge below 700 V. For the -2 kV surge the diodes D1+D3 block the voltage. Configuration "2" relies on the current/energy-limiting resistor R1 to limit the current in the MOV (RV1) to approximately 50 A peak, such that the RV1 clamping voltage is kept well under 1 kV (~700 V). During the +6 kV surge, R2 limits C1 charging current so that the maximum voltage does not exceed 700 V. During the -6 kV surge, D1 blocks the RV1 clamping voltage from reaching C1. In both configurations, the fusible resistor R2 provides protection for component failure.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 6 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
5 Layout
CAUTION!
This is a non-isolated power supply with the low voltage return referenced to the input line (85-265 VAC). Do not touch the unit while it is powered. Power the board using a safety isolation transformer so the high voltage probe return is not referenced to the neutral of the input line. For the drain-to-source voltage waveforms connect the high voltage probe tip to jumper JP1 and the probe ground to test point TP1. For switching current waveforms replace jumper JP1 with a wire loop and use a Tektronix A6302 current probe and AM503 current probe amplifier (with TM501 power module) or equivalent. PCB cut out for 6 kV only
TP1 JP1
Page 7 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
6 Bill of Materials
6.1
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 *Optional **Remove middle pin
Configuration "1", 2 kV
Qty. 1 1 1 2 1 1 1 1 1 1 1 1 1 1 Ref. C1 C2 C3 D1, D3 D2 **J1 J2 *LED1 L1 R2 *R3 U1 U2 VR1 Description 6.8 mF, 400 V, 105 C 0.1 mF, 50 V, ceramic 220 mF 25 V (0.12 W) Glass Passivated Diode 600 V, 1 A, 75 ns Header, 3 pos., 0.156 spacing Header, 2 pos., 0.156 spacing low current 1.5 mH, 0.4 ADC, 0.2 AAC, 600 VDC, 180 W, flame proof, fusible, 3 W; 8.2 kW, 1/4 W Off-line Switcher Optocoupler Zener, 12 V 5% Manufacturer Rubycon Panasonic Panasonic Vishay/Lite On General Instrument Molex Molex Siemens/HP Chilisin Vitrohm (Farnell Components.) Power Integrations Siemens/NEC Diodes Incorporated (08WX7849) 1N4007GP UF4005 26-48-1035 26-48-1025 LG3369/HLMP1790 Part Number 400BXA6R8M10x16 ECU-S1H104KBB
TNY254P SFH615-2/PS2501-1 1N5242B
6.2
Item 15 16
Configuration "2", 6 kV
Qty. 1 1 Ref. RV1 R1 Description Varistor, 275 VAC, 14 mm 100 W, 15 J, 500 VAC Manufacturer Harris/Littlefuse Ohmite Part Number V275LA20A OX 101
(Add the following items to Configuration "1" and subtract D3)
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 8 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
7 Inductor
7.1 Calculation The inductor value can be determined using the TNY253-255 flyback transformer spreadsheet with the following considerations: 1) the frequency value (fL) is 1/2 the line frequency, 25 Hz for 50 Hz, 30 Hz for 60 Hz, to account for half wave rectification. 2) Z factor, the ratio between the secondary losses and the total losses, has to reflect the dominance of the primary losses, as the TinySwitch losses (high Rdson) overshadow the output diode losses. Z factor does not reflect the extra power loss due to R1 and R2. The efficiency used in the spreadsheet is only the efficiency of the converter portion of the supply, it does not include the losses in the input resistor. 3) the output diode rating can be calculated from the formula (VR PIVS/0.8), where PIVS=VMAX+VO-VDS. The inductor can be looked at as a transformer with 1:1 turns ratio, therefore VOR=VO+VD. 4) the output capacitor minimum value is dictated by the output RMS ripple current and the maximum value by the specified maximum output voltage ripple. Select the next higher standard "L" value (for the rated "I") from a qualified vendor (min. 400 VDC voltage rated inductor) like Chilisin, and the smallest DC resistance.
Page 9 of 20
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
7.2
Spreadsheet
OUTPUT UNIT ACDC_TNY_REV1_8_072699.xls: TinySwitch Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Bridge Rectifier Conduction Time Estimate Input Filter Capacitor Continuous Mode Operation or Discontinuous Mode Operation? Continuous 115/230 VAC 5W A A Hz V Minimum Current Limit Maximum Current Limit Minimum Frequency Voltage Drop Between Drain to Source
ACDC_TNY_Rev1.8_072699 INPUT Copyright Power Integrations, Inc. 1999 ENTER APPLICATION VARIABLES VACMIN 77 VACMAX 265 25 fL VO 12 PO 1.2 n 0.65 0.1 Z tC 3 CIN 6.8 MODE OF OPERATION Continuous ('c') or c Discontinuous ('d')?
V V Hz V W mS mF
n
ENTER TinySwitch Parameters Universal TinySwitch TNY254 4W ILIMITMIN 0.23 ILIMITMAX 0.28 fSmin 40000 VDS 10 ENTER Output Diode Parameters Output Diode 500 VR ID 1 VD 1 k 0.8 Design Parameters VMIN VMAX IP DMAX KRP VOR VDRAIN PIVS LP CURRENT WAVEFORM SHAPE PARAMETERS IAVGmax IAVGmin IRMS IR ISP ISRMS IO IRIPPLE IOS
V A V
Diode Maximum Peak Repetitive Reverse Voltage Diode Average Forward Current Diode Forward Voltage Drop Diode Peak to RMS Current Factor (k=0.9 for Schottky, k=0.8 for PN Diode) Minimum DC Input Voltage Maximum DC Input Voltage Peak Primary Current Duty Cycle at Minimum DC Input Voltage Ripple to Peak Current Ratio (0.651 375 0.21 0.252 0.62 13.91 445.63 362 1552
V V A
V V
V mH A A A A A A A A A
0.04 0.00 0.07 0.13 0.22 0.14 0.10 0.09 0.24
Maximum Average Primary Current Minimum Average Primary Current Primary RMS Current Primary Ripple Current Maximum Peak Secondary Current Secondary RMS current Power Supply Output Current Output Capacitor RMS Ripple Current Estimated Short Circuit Current
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 10 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
8.0
8.1
Performance Data
Efficiency TEST EQUIPMENT
INPUT: AC POWER ANALYZER PM1000 (VOLTECH). OUTPUT: ELECTRONIC LOAD PLZ 153 W (KIKUSUI).
E ffi c i e n c y v s. L i n e V o l ta g e C o n fi g . " 2 " , 8 6 C A m b i e n t C o n fi g . " 2 " , 2 8 C A m b i e n t C o n fi g . " 1 " , 2 8 C A m b i e n t
8 0 .0 0 7 5 .0 0 7 0 .0 0 6 5 .0 0 6 0 .0 0 5 5 .0 0 5 0 .0 0 4 5 .0 0 4 0 .0 0 85 105 125
%
145
165 V
185
205
225
245
265
AC, 60 Hz
Figure 8.1.1 - Efficiency vs. Input Voltage.
E f f ic ie n c y v s . O u t p u t P o w e r @ 2 8 C A m b ie n t C o n f ig . " 2 " , 8 5 V A C C o n f ig . " 2 " , 2 6 5 V A C
8 0 .0 0 7 5 .0 0 7 0 .0 0 6 5 .0 0 6 0 .0 0 5 5 .0 0 5 0 .0 0 4 5 .0 0 4 0 .0 0 0 .0 1 0 .0 2 0 .0 3 0 .0 4 0 .0 5 0 .0 6 0 .0 7 0 .0 8 0 .0 9 0 .1 0 IO U T ( A )
C o n fig . " 1 " , 8 5 V A C C o n fig . " 1 " , 2 6 5 V A C
Figure 8.1.2 - Efficiency vs. Output Power.
%
Page 11 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
8.2
Regulation
Line Regulation
Config. "2", 88 C Ambient Config. "1", 28 C Ambient 12.5 12.4 12.3 12.2 12.1 12 85 105 125 145 165 185 205 225 245 265 VAC, 60 Hz Config. "2", 28 C Ambient
Load regulation
Config. "2", 85 VAC, 60 Hz Config. "2", 285 VAC, 60 Hz 12.16 VOUT (V) 12.12 12.08 12.04 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 IOUT (A) Config. "1", 85 VAC, 60 Hz Config. "1", 265VAC, 60 Hz
Figure 5.2.1 - Line Regulation at Full Load, 28 C Ambient.
VOUT (VDC)
Figure 5.2.2 - Load Regulation, at 28 C Ambient.
8.3
Temperature
Output voltage vs Ambient temp.
13 12.5
Thermocouple location External Ambient Internal Enclosure TNYSwitch (U 1) R2 Output Diode (D2) Input Cap (C1)
Output(V)
12 11.5 11 10.5 10 9.5 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 Temp.(C)
Low TAMB (C) 265 VAC, full load 0 2.3 26 39 15 17
High TAMB (C) 85 VAC, full load 84 85.4 100 102 90 91
Figure 8.3.1 - Output Voltage at Full Load (0.1 A) Over -70 C to 90 C Ambient.
Table 8.1 - Components Temperature at Low and High Ambient
Worst case input voltage was selected for the two temperature extremes, 265 VAC (minimum losses) for "Low T" and 85 VAC (maximum losses) for "High T". The temperature dependence of the output voltage can be reduced by using two, lower voltage Zener diodes in series. The unit shut down at 96 C inside internal enclosure.
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 12 of 20
23-April-2001
EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
8.4 Waveforms 8.4.1 Turn-on delay/hold-up time 8.4.1.1 2 kV config."1" 85 VAC
Ch.2
Ch.1
Ch.2
Ch.4,
Ch.4,
Figure 8.4.1.1 - Output Voltage Turn On Delay at Full Load. CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div)
Figure 8.4.1.2 - Output Voltage Hold Up Time. CH1: VOUT (2 V/div), CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div)
8.4.1.2
6 kV config."1" 85 VAC
Ch.1, Ch.2 Ch.2,
Ch.4, Ch.4,
Figure 8.4.1.3 - Output Voltage Turn-on Delay at Full Load. CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div)
Figure 8.4.1.4 - Output Voltage Hold-up Time at Full Load. CH1: VOUT (2 V/div), CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div)
Page 13 of 20
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EPR-000008 - 1.2 W, Universal Input, Non-isolated, TNY254 (EP8) 8.4.2 Switch Current and Drain-to-Source Voltage
23-April-2001
Ch.4
Ch.4
Ch.2
Ch.2
Figure 8.4.2.1 - Full Load at 85 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div)
Figure 8.4.2.2 - Short Circuit at 85 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div)
Ch.4
Ch.4
Ch.2 Ch.2
Figure 8.4.2.3 - Full Load at 265 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div)
Figure 8.4.2.4 - Short Circuit at 265 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div)
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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23-April-2001
EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
VOR Vin
Figure 8.4.2.5 - Drain-Source Voltage (VDS). CH2 (20 V/div). VOR=VO+VD=13.6 V
8.4.3 Output Voltage Ripple
CH1
CH1
CH4
CH4
Figure 8.4.3.1 - Switching Ripple at Full Load. CH1: VOUT (50 mV/div), CH4: IOUT (50 mA/div)
Figure 8.4.3.2 - Switching Frequency Ripple at Full Load. CH1: VOUT (50 mV/div), CH4: IOUT (50 mA/div)
Page 15 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
8.5
Transient Response
CH1
CH1
CH4
CH4
Figure 8.5.1 - Output Voltage Transient Response at 115 VAC 50-100% Load Change. CH1: VOUT (50 mV/div), CH2: IOUT (50 mA/div)
Figure 8.5.2 - Output Voltage Transient Response at 230 VAC 50-100% Load Change. CH1: VOUT (50 mV/div), CH2: IOUT (50 mA/div)
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 16 of 20
23-April-2001
EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
8.6
Surge Voltage Immunity (2 kV and 6 kV, 1.2/50 ms per IEC1000-4-5)
Two series of surge tests were performed: Configuration "1" (2 kV), Fig. 8.6.1 and configuration "2" (6 kV), Fig. 8.6.2 passed 20 surges each at 45 seconds apart; 10 surges with positive (Fig. 8.6.3) and 10 with negative polarity (Fig. 8.6.4), all at high input line and full load. The 45 seconds delay between surges allows the energy rated components (R1, R2 and RV1) to cool down. High input line is the worst case condition as the input capacitor (C1) reaches highest voltage therefore minimizing margin for TinySwitch breakdown voltage. R2 limits the charging current during a +voltage surge such that C1 peak voltage does not exceed the TNY254 breakdown voltage. R1 limits the maximum surge current to approximately 50 A, the value at which the clamping voltage of the varistor is characterized (<700 V). The 6 kV, 1.2/50 ms pulse at 700 V clipping level is approximately 100 ms (see Fig. 8.7.2). From the graph in Fig. 8.6.5, it can be inferred that the unit will survive 10 k surges of -6 kV (more of +6 kV as C1 can divert ~0.3 J). Reducing the value of R1 would reduce the total number of 6 kV pulses the unit can survive.
L J1-1
J1-1 L
C1 85-265 VAC, 50/60 Hz J1-3 D3 R2 6.8 mF 400 V D1
+
85-265 VAC, 50/60 Hz RV1 J1-3 N 100 W, surge 180 W, 3 W, fusible R1 R2
C1 6.8 mF 400 V D1
+
N
1N4007 180 W, 3 W, fusible
Figure 8.6.1 - Configuration "1", 2 kV.
1N4007
1N4007
Figure 8.6.2 - Configuration "2", 6 kV.
Page 17 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
VRV1
VAC Varistor Clamp GND
200 V/div
Instantaneous Line Voltage
200 V/div
VAC
Figure 8.6.3 - RV1 Voltage During +6 kV, 1.2/50 ms Surge.
VRV1
Figure 8.6.4 - RV1 Voltage During -6 kV, 1.2/50 ms Surge.
The pre-trigger voltage is the instantaneous line voltage. The RV1 voltage is post-trigger and is referenced to the ground.
Figure 8.6.5 - Varistor Life (Number of Surges) as a Function of the Rectangular Pulse Amplitude and its Duration.
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
Revision History
Date 5-Aug-1999 30-Aug-1999 7-Sep-1999 16-Oct-1999 18-Nov-1999 24-Nov-1999 23-Feb-2000 23-Mar-2000 9-Oct-2000 23-Apr-2001 Author S. L. S. L S. L S. L S. L S. L S. L S. L S. L S. L Rev 1 2 3 4 5 6 7 8 9 10 Description First Draft Second Draft Third Draft Fourth Draft Fifth Draft Sixth Draft Seventh Draft Release Pg.6, D1+D2 to D1+D3 Pg.8, 6.2 Config. Items 4 and 10
Page 19 of 20
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EPR-000008 - 1.2 W Universal Input Non-Isolated TNY254
23-April-2001
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. PI Logo, TOPSwitch and TinySwitch are registered trademarks of Power Integrations, Inc. (c) 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 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
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