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Title Specification Application Author Document Number Date Revision
21 W Standby Power Supply using TNY280P Input: 85 - 295 VAC (110 - 420 VDC) Outputs: 5 V / 4 A; 15 V / 67 mA General PC-Standby Supply Power Integrations Applications Department DER-114 June 28, 2006 1.0
Summary and Features * * * * * High standby efficiency: PIN < 0.70 W @ POUT = 0.5 W, at 230 VAC input Under-voltage lockout (UVLO) function: glitch-free startup and shutdown Two means of implementing output overvoltage protection (OVP) EEL22 transformer core meets clearance and creepage requirements Output overload, short circuit and open feedback loop protection
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.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
Table Of Contents
Introduction .................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic ...................................................................................................................5 Circuit Description.......................................................................................................6 4.1 Input Rectifier & filter ...........................................................................................6 4.2 TNY280 Primary ..................................................................................................6 4.3 Output Rectification .............................................................................................7 4.4 Output Feedback .................................................................................................7 4.5 UV Lockout ..........................................................................................................7 4.6 OV Protection ......................................................................................................7 5 PCB Layout.................................................................................................................9 6 Bill Of Materials.........................................................................................................10 7 Transformer Specification .........................................................................................11 7.1 Electrical Diagram..............................................................................................11 7.2 Electrical Specifications .....................................................................................11 7.3 Materials ............................................................................................................11 7.4 Transformer Build Diagram................................................................................12 7.5 Transformer Construction ..................................................................................12 8 Transformer Spreadsheets .......................................................................................13 9 Performance Data.....................................................................................................16 9.1 Efficiency ...........................................................................................................16 9.2 No-load Input Power ..........................................................................................16 9.3 0.5 W (5 V, 0.1 A) Load Input Power .................................................................17 9.4 Available Standby Output Power .......................................................................17 9.5 Regulation .........................................................................................................18 9.5.1 Load ...........................................................................................................18 9.5.2 Line.............................................................................................................18 10 Thermal Performance............................................................................................19 11 Waveforms ............................................................................................................20 11.1 Drain Voltage and Current, Normal Operation...................................................20 11.2 Drain Voltage & Current Startup Profile .............................................................21 11.3 Output Voltage Startup Profile ...........................................................................21 11.4 OV Shutdown ....................................................................................................22 11.5 Load Transient Response (3 A to 4 A Load Step) .............................................23 11.6 Output Ripple Measurements ............................................................................24 11.6.1 Ripple Measurement Technique.................................................................24 11.6.2 Measurement Results.................................................................................25 12 Design Notes:........................................................................................................26 13 Revision History ....................................................................................................27 Important Note: 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. 1 2 3 4
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
1 Introduction
This engineering report describes a universal input 5 V, 4 A power supply designed around a TNY280P device from the TinySwitch-III family of ICs. Although designed as an auxiliary or bias supply for a personal computer (PC) power supply, this design can also be used as a general-purpose evaluation platform for TinySwitch-III devices. Typically, PC power supplies have a power factor corrected (PFC) input stage. However, since the bias supply must operate before the PFC stage is active, this supply has been designed for universal input operation. Input rectification and input storage capacitance have been included, for evaluation purposes. This stage and the EMI filter components would normally be part of the main PC supply, in an actual application. This report contains the power supply specification, the circuit diagram, a complete bill of materials (BOM), the PI Xls transformer spreadsheet design results, complete transformer documentation, the printed circuit board (PCB) layout and relevant performance data.
Figure 1- Populated Circuit Board Photograph.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
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 Current 2 Total Output Power Continuous Output Power Efficiency Full Load Ambient Temperature Symbol VIN fLINE Min 85 47 Typ Max 295 64 0.3 5.25 50 4 18 67 21 76 0 50 Units VAC Hz W V mV A V mA W % C
Measured at POUT 25 C Free convection, sea level
o
Comment
Equivalent to 100 - 420 VDC
50/60
VOUT1 VRIPPLE1 IOUT1 VOUT2
4.75
5
5% 20 MHz bandwidth 100 mA minimum load on VOUT1 & 40 mA load on auxiliary output
12
15
POUT TAMB
o
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
3 Schematic
Figure 2 - Circuit Diagram.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
4 Circuit Description
This dual output converter is configured as a Flyback. The main output provides 4 A at 5 V, while the bias winding on transformer T1 is used to generate a 15 V output that can supply up to 67 mA. The converter will operate over an input voltage range of 85 - 295 VAC or 100 - 420 VDC. The 5 V output is referenced to a TL431 located on the secondary side, and feedback is passed back to the primary through optocoupler (U2). 4.1 Input Rectifier & filter This circuit is designed for standby applications and components F1, RT1, D1-D4 & C1 are only provided for standalone testing. Fuse F1 will effectively isolate the converter from the supply source in the event of short circuit failure. Thermistor RT1 limits the inrush current at startup. Diodes D1, D2, D3 & D4 form a bridge rectifier, which charges the bulk storage capacitor C1. 4.2 TNY280 Primary The TNY280P device (U1) is an integrated circuit, which includes a power MOSFET, an oscillator, control, start-up and protection functions. A clamp circuit (D5, VR1, C3, R1 & R3) limits the voltage that appears on the drain of U1 each time its MOSFET turns off. During normal operation VR1 does not conduct and clamping is performed by D5, C3, R1 & R3. Typically, VR1 will only conduct during fault conditions such as overload. This approach allows the RCD clamp (R1, R3, C3 & D5) to be sized for normal operation, which maximizes efficiency at light load. The output of the bias/auxiliary supply winding is rectified by diode D6 and filtered by capacitor C4. The rectified and filtered output of the bias winding (terminals J5 & J6) can be used to power external circuitry on the primary side, such as the PFC and main converter control circuits. The bias winding is also used to supply current to the TNY280 BYPASS/MULTIFUNCTION (BP/M) pin during steady state operation. The value of R4 is selected to deliver the IC supply current to the BP/M pin, thereby inhibiting the internal high-voltage current source that normally charges the BP/M pin capacitor (C2). This results in reduced input power consumption under light load and no load conditions. Capacitor C2 provides high frequency decoupling of the internally generated 5.85 V IC supply voltage. Three different capacitor values could be used for C2, which would select one of three internal current limit sets. A 0.1 uF capacitor was used in this design, which selects the standard current limit set for a TNY280P. The transistor of optocoupler U2 pulls current out of the ENABLE/UNDER-VOLTAGE (EN/UV) pin of U1. The IC keeps switching as long as the current drawn from its EN/UV pin is less than 90 A. It stops switching whenever the current drawn from the EN/UV pin exceeds that threshold, which ranges from 90 A to 150 A (with the typical value being 115 A). By enabling and disabling switching pulses, the feedback loop regulates the output voltage of the power supply.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
An internal state machine sets the MOSFET current limit to one of four levels, depending on the main output load current. This ensures that the effective switching frequency remains above the audible frequency range. The lowest current limit (used at no-load) makes the transformer flux density so low that dip-varnished transformers produce no perceptible audible noise. 4.3 Output Rectification Diode D7 rectifies the main output. Low ESR capacitors C7, C8 & C9 attenuate the switching ripple. A post filter (L1 & C10) further reduces switching ripple and noise on the main output. 4.4 Output Feedback Resistors R6 and R7 form a voltage divider network. A portion of the output voltage is fed into the input terminal of the TL431 (U3). The TL431 varies its cathode voltage in an attempt to keep its input voltage constant (equal to 2.5 V, 2%). As the cathode voltage changes, the current through the LED and transistor within U2 change. Whenever the EN/UV pin current exceeds its threshold, the next switching cycle is disabled. Whenever the EN/UV pin current falls below the threshold, the next switching cycle is enabled. As the load is reduced, the number of enabled switching cycles decreases, which lowers the effective switching frequency and the switching losses. This results in almost constant efficiency down to very light loads, which is ideal for meeting energy efficiency requirements. Capacitor C12 rolls off the gain of U3 with frequency, to ensure stable operation. Capacitor C11 prevents the output voltage from overshooting at startup. 4.5 UV Lockout Optional resistors R11 and R12-connected between the DC bus and the EN/UV pin of U1-enable the under-voltage lockout function. When these resistors are used, start-up is inhibited until the current into the EN/UV pin exceeds 25 A. The values of R11 and R12 sets a startup voltage threshold that prevents output voltage glitches when the input voltage is abnormally low, such as when the AC input capacitor is discharging during shutdown. Additionally, the UVLO status is checked whenever a loss of regulation occurs-such as during an output overload or short-circuit. This effectively latches U1 off until the input voltage is removed and reapplied. With the values of R11 and R12 shown in figure 2, the UVLO threshold is approximately 100 VDC (71 VAC). 4.6 OVP This supply has two different overvoltage protection circuits. The first OVP function is provided by VR2 and the latching shutdown function built into U1. If the feedback loop became an open circuit-due to the failure of U2, for example-the main output voltage and the bias winding voltage would both rise. Once the bias voltage exceeded the sum of the voltage across VR2 and the BP/M pin voltage, current would flow into the BP/M pin. When that current exceeds the OV shutdown threshold (5.5 mA), the latching shutdown function is triggered and MOSFET switching is disabled. MOSFET switching remains disabled until the BP/M pin capacitor (C2) is discharged below 4.8 V.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
The second OVP function is provided by VR3, U4 and R10, and is enabled when jumpers JP1 and JP2 are installed (forms a second feedback loop). If the primary feedback loop became an open circuit, the output voltage would rise. The EN/UV pin would be pulled low once the output voltage exceeded the voltage across VR3 and the LED within U4. The output voltage would then be regulated at a slightly higher voltage than that of the primary feedback loop.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
5 PCB Layout
Figure 3 - Printed Circuit Layout.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
6 Bill Of Materials
Item 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 32 33 34 35 36 37 38 39 Qty 1 2 1 1 1 1 3 1 1 1 4 2 1 1 1 2 3 1 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 2 1 1 1 1 Part Ref C1 C2 C12 C3 C4 C5 C6 C7 C8 C9 C10 C11 C13 D1 D2 D3 D4 D5 D6 D7 F1 HS1 J1 J4 J2 J5 J6 J3 JP1 JP2 L1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 RT1 T1 U1 U2 U4 U3 VR1 VR2 VR3 Value 100 F 100 nF 1 nF 100 F 1 nF 470 pF 1500 F 470 F 2.2 F 22 nF 1N4007 1N4937 15TQ060 3.15 A 6032B-TT CON1 CON1 CON1 J 3.3 H 200 k 3 k 30 16 k 33 10 k 47 1 k 100 2.0 M 4.7 16 EEL22 TNY280P PC817A TL431 P6KE150 A 1N5247B 1N5231C Description 100 F, 450 V, Electrolytic, Low ESR, (18 x 30) 100 nF, 50 V, Ceramic, X7R 1 nF, 1 kV, Disc Ceramic 100 F, 35 V, Electrolytic, Gen. Purpose, (8 x 11.5) 1 nF, Ceramic, Y1 470 pF, 100 V, Ceramic, X7R 1500 F, 10 V, Electrolytic, Very Low ESR, 22 m, (10 x 25) 470 F, 10 V, Electrolytic, Low ESR, 120 m, (8 x 12) 2.2 F, 50 V, Electrolytic, Gen. Purpose, (5 x 11) 22 nF, 630 V, Film 1000 V, 1 A, Rectifier, DO-41 600 V, 1 A, Fast Recovery Diode, 200 ns, DO-41 60 V, 15 A, Schottky, TO-220AC 3.15 A, 250 V, Fast, TR5 HEATSINK, Straight Fin, 8.3 C/W, TO-220 Test Point, BLK,THRU-HOLE MOUNT Test Point, WHT,THRU-HOLE MOUNT Test Point, RED,THRU-HOLE MOUNT Wire Jumper, Non insulated, 22 AWG, 0.2 in 3.3 H, 5.5 A, 8.5 x 11 mm 200 k, 5%, 1/2 W, Carbon Film 3 k, 5%, 1/2 W, Carbon Film 30 , 5%, 1/2 W, Carbon Film 16 k, 5%, 1/4 W, Carbon Film 33 , 5%, 1/4 W, Carbon Film 10 k, 1%, 1/4 W, Metal Film 47 , 5%, 1/4 W, Carbon Film 1 k, 5%, 1/4 W, Carbon Film 100 , 5%, 1/4 W, Carbon Film 2.0 M, 5%, 1/4 W, Carbon Film 4.7 , 5%, 1/4 W, Carbon Film NTC Thermistor, 16 , 2.7 A Bobbin, EEL22, Vertical, 10 pins TinySwitch-III, TNY280P, DIP-8C Opto coupler, 35 V, CTR 80-160%, 4DIP 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92 150 V, 5 W, 5%, TVS, DO204AC (DO15) 17 V, 5%, 500 mW, DO-35 5.1 V, 2%, 500 mW, DO-35 Mfg Part Number EPAG451ELL101M M35S B37987F5104K000 / ECU-S1H104KBB ECK-D3A102KBP KME35VB101M6X1 1LL 440LD10 ECU-S2A471KBA EKZE100ELL152MJ 25S ELXZ100ELL471MH 12D EKME500ELL2R2M E11D ECQ-E6223KF 1N4007 1N4937 15TQ060 370 1315 041 6032B-TT 5011 5012 5010 298 R622LY-3R3M CFR-50JB-200K CFR-50JB-3K0 CFR-50JB-30R CFR-25JB-16K CFR-25JB-33R MFR-25FBF-10K0 CFR-25JB-47R CFR-25JB-1K0 CFR-25JB-100R CFR-25JB-2M0 CFR-25JB-4R7 CL170 YC-2207 TNY280P PC817X1 TL431CLP P6KE150A 1N5247B 1N5231C Mfg Nippon ChemiCon Epcos/Panasonic Panasonic Nippon ChemiCon Vishay Panasonic Nippon ChemiCon Nippon ChemiCon Nippon ChemiCon Panasonic Vishay Vishay International Rectifier Wickmann AAVID/Thermalloy Keystone Keystone Keystone Alpha Toko Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Thermometrics Ying Chin Power Integrations Sharp Texas Instruments Vishay Microsemi Microsemi
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
7 Transformer Specification
7.1 Electrical Diagram
Figure 4 - Transformer Electrical Diagram.
7.2
Electrical Specifications
Electrical Strength Primary Inductance Resonant Frequency 1 second, 60 Hz, from Pins 1-5 to Pins 7-10 Pins 1-3, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-3, all other windings open Pins 1-3, with Pins 7-10 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 1084 H, -/+10% 1200 kHz (Min.) 28 H (Max.)
Primary Leakage Inductance
7.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description Core: PC40 - EEL22 with air gap GAPPED ALG VALUE- 131nH/T2 Bobbin: EEL-22, 10 Pin Bobbin (Ying Chin YC-2207/ Pin Shine P-2204 or equivalent) Magnet Wire: #28 AWG Heavy Nyleze Copper Foil 12 mm X 0.1 mm Tape: 3M #44 Polyester Web Margin Tape 3 mm wide Tape, 3M 1298 Polyester Film 18.5 mm, 0.002" Thick Tape, 3M 1298 Polyester Film 12.5 mm, 0.002" Thick Tape, 3M 1298 Polyester Film 4 mm, 0.002" Thick Varnish
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
7.4
Transformer Build Diagram
Figure 5a - Transformer Build Diagram.
Figure 5b - Secondary Tape Preparation.
Figure 5c - Secondary Tape Cross-Section
7.5
Transformer Construction
Bobbin Preparation Primary Margin Primary WD#1 Basic Insulation Secondary Margin Secondary WD # 2 Basic Insulation Bias Margin Bias Winding WD # 3 Basic Insulation Primary Margin Primary WD#4 Outer Wrap Core Assembly Varnish Set up Bobbin with pins oriented to the left hand side Apply 3.0 mm wide margin to both sides of bobbin using item [5]. Match height of primary windings. Start at Pin 3. Wind 30 turns of item [3] in approximately 1 layer. Add 1 Layer of Tape [7] for insulation. Wind remaining 30 primary turns, finish on Pin 2. Use two layers of item [6] for basic insulation. Apply 3.0 mm wide margin to both sides of bobbin using item [5]. Match height of secondary winding. Prepare Copper Foil as shown in figure 5b & 5c above. Starting at Pin 10, wind 5 turns of item [4]. Finish at Pin 7. Use two layers of item [6] for basic insulation. Apply 3.0 mm wide margin to both sides of bobbin using item [5]. Match height of bias winding Start at Pins 4. Wind 14 turns of item [3]. Spread turns evenly across bobbin. Finish on Pins 5. Use two layers of item [6] for insulation Apply 3.0 mm wide margin to both sides of bobbin using item [5]. Match height of 1 layer of primary winding. Start at Pin 2. Wind 31 turns of item [3] and end at pin 1. Wrap windings with 2 layers of tape item [6]. Assemble cores item [1] on bobbin and secure using item [8]. Dip Varnish using item [9]
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
8 Transformer Spreadsheets
(Note - Output current is made 4.20 A in the spreadsheet to account for load on the auxiliary output) ACDC_TinySwitchIII_020706; Rev.1.6; ACDC_TinySwitch-III_020706_Rev1-6.xls; Copyright Power TinySwitch-III Continuous/Discontinuous Integrations 2006 INPUT INFO OUTPUT UNIT Flyback Transformer Design Spreadsheet ENTER APPLICATION VARIABLES VACMIN 85 Volts Minimum AC Input Voltage VACMAX 295 Volts Maximum AC Input Voltage fL 50 Hertz AC Mains Frequency VO 5.00 Volts Output Voltage (at continuous power) Power Supply Output Current (corresponding to peak power) IO 4.20 Amps Power 21 Watts Continuous Output Power Efficiency Estimate at output terminals. Enter 0.7 if no better data available n 0.75 Z Factor. Ratio of secondary side losses to the total losses in the power supply. Use 0.5 if Z 0.50 no better data available tC 3.00 mSeconds Bridge Rectifier Conduction Time Estimate CIN 100.00 100 uFarads Input Capacitance ENTER TinySwitch-III VARIABLES TinySwitch-III TNY280 Chosen Device
TNY280 TNY280 Standard Current Limit 0.698 0.750 0.802 124000 66.825
User defined TinySwitch-III Enter "RED" for reduced current limit (sealed adapters), "STD" for standard current limit or "INC" for increased current limit (peak or higher power applications) Minimum Current Limit Typical Current Limit Maximum Current Limit Minimum Device Switching Frequency I^2f (product of current limit squared and frequency is trimmed for tighter tolerance) Reflected Output Voltage (VOR < 135 V Recommended) TinySwitch-III on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (KP < 6) Transient Ripple to Peak Current Ratio. Ensure KP_TRANSIENT > 0.25
Chose Configuration ILIMITMIN ILIMITTYP ILIMITMAX fSmin I^2fmin VOR VDS VD KP KP_TRANSIENT
STD
Amps Amps Amps Hertz A^2kHz Volts Volts Volts
100.00
100 10 0.5 0.49 0.27
ENTER BIAS WINDING VARIABLES VB 15 VDB NB VZOV UVLO VARIABLES V_UV_TARGET V_UV_ACTUAL RUV_IDEAL RUV_ACTUAL
15.00 0.70 13.64 21.00
Volts Volts Volts
Bias Winding Voltage Bias Winding Diode Forward Voltage Drop Bias Winding Number of Turns Over Voltage Protection zener diode.
112.88 109.70 4.43 4.30
Volts Volts Mohms Mohms
Target under-voltage threshold, above which the power supply with start Typical start-up voltage based on standard value of RUV_ACTUAL Calculated value for UV Lockout resistor Closest standard value of resistor to RUV_IDEAL
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EEL22 EEL22 Core EEL22 EEL22_BOBB Bobbin IN
P/N: P/N:
User-Selected transformer core PC40EE22/29/6-Z EEL22_BOBBIN
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DER-114
AE LE AL BW M L NS 3.20 3.00 5
PC Standby Power Supply - TNY280P
0.358 6.32 1400 18 3.2 3 5 cm^2 cm nH/T^2 mm mm
June 28, 2006
Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance 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 CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP_TOLERANCE NP ALG BM BAC ur LG BWE OD INS DIA AWG CM CMA
103 417
Volts Volts
Minimum DC Input Voltage Maximum DC Input Voltage
0.52 0.30 0.6980 0.3448 0.44
Amps Amps Amps Amps
Duty Ratio at full load, minimum primary inductance and minimum input voltage Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current
10.00
1084 10 91 131 2671 660 1967 0.31 34.8 0.383 0.06 0.324 28 161 364
uHenries % nH/T^2 Gauss Gauss mm mm mm mm mm AWG Cmils Cmils/Amp
Typical Primary Inductance. +/- 10% to ensure a minimum primary inductance of 985 uH Primary inductance tolerance Primary Winding Number of Turns Gapped Core Effective Inductance Maximum Operating Flux Density, BM<3000 is recommended AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < 500)
TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP 12.69 ISRMS 7.75 IRIPPLE 6.51 CMS AWGS VOLTAGE STRESS PARAMETERS VDRAIN PIVS 647 28 1550 18
Amps Amps Amps Cmils AWG
Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value)
Volts Volts
Maximum Drain Voltage Estimate (Assumes 20% zener clamp tolerance and an additional 10% temperature tolerance) Output Rectifier Maximum Peak Inverse Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 5 Volts
Main Output Voltage (if unused, defaults to
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DER-114
IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 Recommended Diodes CMS1 AWGS1 DIAS1 ODS1
PC Standby Power Supply - TNY280P
4.200 21.00 0.500 5.00 7.749 6.51 28 MBR1060 1550 18 1.03 2.32 Cmils AWG mm mm Amps Watts Volts Amps Amps Volts
June 28, 2006
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 Recommended Diodes for this output Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency (4 A Load on 5 V Output)
Figure 6 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
9.2
No-load Input Power
Figure 7 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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DER-114 9.3
PC Standby Power Supply - TNY280P
June 28, 2006
0.5 W (5 V, 0.1 A) Load Input Power
Figure 8 - 0.5 W Load - Input Power with & without bias winding.
9.4 Available Standby Output Power The chart below shows the available output power vs. line voltage for an input power consumption of 1, 2 & 3 watts respectively. ON/OFF control is valuable in maintaining high efficiency under light load conditions, and helps meet many standby requirements.
Figure 9 - Available Standby Output Power.
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DER-114 9.5 Regulation
PC Standby Power Supply - TNY280P
June 28, 2006
9.5.1 Load
Figure 10 - Load Regulation, Room Temperature.
9.5.2 Line
Figure 11 - Line Regulation, Room Temperature, Full Load.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
10 Thermal Performance
Temperature measurement of key components were taken using T-type Thermocouples. The thermocouples were attached directly to the SOURCE pin of the TNY280P device and the case of the output rectifier. The thermocouples were glued to the output capacitor & to the external core and winding surfaces of the transformer T1. The cooling of the TNY280P is achieved through the copper plane on the PCB. It is necessary to provide adequately large copper area on the PCB attached to the SOURCE pins (5, 6, 7 and 8) of the DIP-8 package, to achieve the required cooling (se figure 3). These results indicate an acceptable temperature rise of key components when ambient is increased to 50 C.
Item Ambient Transformer (T1) core Transformer (T1) coil Tiny-Switch (U1) Rectifier (D7) case 25 49.9 52.4 62.3 75 Temperature (C) 85 VAC 115 VAC 230 VAC 25 45 50.6 56.3 75 25 44 49.6 49 74
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
11 Waveforms
11.1 Drain Voltage and Current, Normal Operation
Figure 12 - 90 VAC, Full Load. Upper: VDRAIN, 50 V / div Lower: IDRAIN, 0.4 A, 1 s / div
Figure 13 - 283 VAC, Full Load Upper: VDRAIN, 100 V / div Lower: IDRAIN, 0.4 A, 0.5 s / div
Figure 14 - 90 VAC, Full Load VDRAIN, 50 V, 10 s / div.
Figure 15 - 283 VAC, Full Load VDRAIN, 100 V, 20 s / div.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
11.2 Drain Voltage & Current Startup Profile
Figure 16 - Start-up Profile, 90 VAC Upper: VDRAIN, 200 V / div Lower: IDRAIN, 0.4 A, 50 ms / div
Figure 17 - Start-up Profile, 283 VAC Upper: VDRAIN, 200 V / div Lower: IDRAIN, 0.4 A, 50 ms / div
11.3 Output Voltage Startup Profile
Figure 18 - Start-up Profile, 90 VAC (No Load) VOUT, 1 V, 5 ms / div.
Figure 19 - Start-up Profile, 90 VAC (Full Load) VOUT, 1 V, 5 ms / div.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
Figure 20 - Start-up Profile, 283 VAC (No Load) VOUT, 1 V, 5 ms / div
Figure 21 - Start-up Profile, 283 VAC (Full Load) VOUT, 1 V, 5 ms / div.
11.4 OV Shutdown Two different OV Protection circuits can be designed with TinySwitch-III. Figure 22 shows operation of primary side OV protection circuit (JP1 and JP2 not installed) and feedback disconnected to cause OV condition at the output. Figure 23 shows OV protection offered by VR3, U4 & R10 circuit (Feedback disconnected during operation to cause OV condition at output).
Figure 22 - 5 V Output Voltage. VOUT, 2 V, 200 ms / div
Figure 23 - 5 V Output Voltage. VOUT, 2 V, 20 ms / div.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
11.5 Load Transient Response (3 A to 4 A Load Step) In the figures shown below, signal averaging was used to enable better viewing of 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 only the contribution from the load step response. The waveforms (Figures 24 and 25) show an instantaneous voltage change of 70 mV for a 75% - 100% step load change. Increasing the size of the output filter capacitor minimizes the 70 mV change.
Figure 24 - Transient Response, 90 VAC Upper: VOUT, 100 mV, 2 ms / div Lower: IOUT, 3 A to 4 A Load Step
Figure 25 - Transient Response, 283 VAC Upper: VOUT, 100 mV, 2 ms / div Lower: IOUT, 3 A to 4 A Load Step
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
11.6 Output Ripple Measurements 11.6.1 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 26 and Figure 27. 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 26 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 27 - 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-114
PC Standby Power Supply - TNY280P
June 28, 2006
11.6.2 Measurement Results
Figure 28 - 5 V Ripple, 90 VAC, Full Load. VOUT, 20 mV, 10 ms / div
Figure 29 - 5 V Ripple, 283 VAC, Full Load. VOUT, 20 mV, 10 ms / div
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
12 Design Notes:
1. Use of sufficient copper area directly under the TNY280P device, connected to the SOURCE pins of the IC is recommended for effective cooling. Generally, 1 square inch of symmetrical copper (2 oz) should be sufficient. However, actual temperature measurements should be used to determine adequacy. This is especially important when using the TinySwitch-III devices at or near the power levels specified on the datasheet output power table. 2. A dummy load (R2 in figure 2) was used in this design to ensure appropriate line & load regulation of the auxiliary output. Since this output is not directly regulated, it has a slightly higher output voltage when unloaded. The value of R13 should be selected, based on the current drawn by the external circuit that loads the auxiliary output. The filtering of the auxiliary output, and the need for an additional filter stage should be carefully evaluated, based on the load circuit's requirements. 3. R13 & C4 form a RC filter to reduce the ripple voltage on the auxiliary output 4. In many applications, the snubber circuit (R3, C3 & R1) can be eliminated, depending on the EMC compliance requirements of the system. 5. The size and specification of the output diode (D7) heat sink depends on load and operating conditions. In some designs, where augmented airflow is available, a small surface-area heat sink may be sufficient.
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
13 Revision History
Date Author 28-June-06 RJ Revision 1.0 Description & changes Initial Release Reviewed PV / JJ / KM
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DER-114
PC Standby Power Supply - TNY280P
June 28, 2006
For the latest updates, visit our website: 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. PATENT INFORMATION 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, DPA-Switch and EcoSmart are registered trademarks of Power Integrations. PI Expert and PI FACTS are trademarks of Power Integrations. (c) Copyright 2005 Power Integrations.
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