TNY268P DER-11 TNY268 5125BA 1N4007GP SB540 BZX79 BAV20 P6KE180A PC817D - Datasheet Archive

 

Title 15W power supply using TNY268P Specification Input: 120 - 420 Vdc Output: 5V/3A, 13V/10mA Application PC Standby Author

 

Design Example Report Title 15W power supply using TNY268P TNY268P Specification Input: 120 - 420 Vdc Output: 5V/3A, 13V/10mA Application PC Standby Author Power Integrations Applications Department Document Number DER-11 DER-11 Date February 4, 2004 Revision 1.0 Summary and Features This report details the design of an isolated Flyback converter for a PC Standby power supply. · · · · · High light load efficiency Over 0.4W out at 1W in, as measured in the PC PSU Total output power 15 W with TNY268P TNY268P and EE19 core Typical Efficiency 79 % Meets ± 5 % output voltage regulation over line and load changes 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. Applications Hotline: Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 Table Of Contents 1 2 3 4 5 6 Introduction. 4 Power Supply Specification . 5 Schematic. 6 PCB Layout . 7 Bill Of Materials . 8 Transformer. 9 6.1 Transformer Winding. 9 6.2 Electrical Specifications. 9 6.3 Transformer Construction. 10 6.4 Materials. 10 6.5 Winding Instructions . 11 6.6 Design Notes:. 11 7 Transformer Design Spread Sheet. 12 Performance Data . 14 7.1 Light Load Input and Output Power Comparison . 15 7.2 Efficiency comparison, standalone . 16 8 Output Ripple Measurements. 17 8.1 Ripple Measurement Technique . 17 8.2 Output Voltage Ripple . 18 9 Revision History . 18 Notes . 19 Page 2 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 List Of Figures Figure 1 ­ Power Supply Prototype ­ Top View. 4 Figure 2 ­ Power Supply Prototype ­ Bottom View . 4 Figure 3 ­ TNY268 TNY268 Flyback Converter ­ 15 W, 5V 3A, 13V 10 mA. 6 Figure 4 ­ PCB Layout . 7 Figure 5 ­ Transformer Winding. 9 Figure 6 ­ Transformer Construction. 10 Figure 7 ­ Input vs. Output power at 115 Vac. 15 Figure 8 ­ Input vs. Output power at 230 Vac. 15 Figure 9 ­ Efficiency versus output current at 115 Vac. 16 Figure 10 ­ Efficiency versus output current at 230 Vac. 16 Figure 11 ­ Oscilloscope Probe Prepared for Ripple Measurement. 17 Figure 12 ­ Oscilloscope Probe with Probe Master 5125BA 5125BA BNC Adapter . 17 Figure 13 ­ 5V Output Voltage Ripple at VIN = 115 Vac, I5V = 3 A . 18 List Of Tables Table 1 ­ Power Supply Specification _ 5 Table 2 ­ Bill of Materials _ 8 Table 3 ­ Transformer Electrical Parameters_ 9 Table 4 ­ Transformer BOM_ 10 Table 5 ­ Power Supply Design Parameters _ 11 Important Notes: Although the prototype hardware is designed to satisfy safety isolation requirements, this 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. The layout shown in this report has been engineered to follow Power Integrations' design guidelines to minimize EMI and susceptibility. Changing the layout may worsen EMI and other aspects of performance. 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. Page 3 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 1 Introduction This document is an engineering report showing the performance characteristics of a 15W Flyback converter with 120­420Vdc (PFC application) input, 5V 3A isolated output, and 13V 10mA non-isolated output. This design uses TinySwitch-II ­ an integrated IC comprising a high voltage MOSFET, and PWM controller. This document contains power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. The photos of power supply prototype are shown in Figure 1 and Figure 2. Measurements were taken both with the prototype standalone, and in the PC power supply. Figure 1 ­ Power Supply Prototype ­ Top View Figure 2 ­ Power Supply Prototype ­ Bottom View Page 4 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 Note: Y-cap is for testing the unit standalone. Otherwise, The common-mode noise may affect the input power measurements. 2 Power Supply Specification Description Input Voltage Outputs Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Symbol Min VIN 120 VOUT1 VRIPPLE1 IOUT1 4.75 VOUT2 Typ Units Comment 420 5.0 Max Vdc PFC Standby 5.25 50 3 V mV A 20 MHz Bandwidth 13 ± 5% isolated V VRIPPLE2 130 mV 20 MHz Bandwidth Output Current 2 IOUT2 10 mA non-isolated Continuous Output Power POUT 15 W 79 % Output Ripple Voltage 2 Efficiency Ambient Temperature TAMB 0 40 o C At full load Free convection, Sea level Table 1 ­ Power Supply Specification Page 5 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 3 Schematic Figure 3 ­ TNY268 TNY268 Flyback Converter ­ 15 W, 5V 3A, 13V 10 mA Page 6 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 4 PCB Layout Figure 4 ­ PCB Layout Note: 1. The schematic and PCB layout have some components as OPTIONS, which are not used in the prototype. 2. The prototype PCB layout may not match the schematic, due to modifications made to meet the specifications. Page 7 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 5 Bill Of Materials Item Qty Reference Description 1 1 C1 0.01 µF, 1KV, Ceramic capacitor, Z5U 2 1 C2 1000 pF, 1KV, Ceramic capacitor, Z5U 3 1 C3 0.1 µF, 50V, Ceramic capacitor, X7R 4 1 C4 1500 µF, 10V, Electrolytic capacitor Low ESR, (Rubycon ZL series or equivalent) 5 1 C5 1000 µF, 10V, Electrolytic capacitor Low ESR, (Rubycon ZL series or equivalent) 6 1 C6 470 µF, 10V, Electrolytic capacitor Low ESR, (Rubycon ZL series or equivalent) 7 1 C7 470 pF, 50V, Ceramic capacitor, NPO 8 1 C8 47 µF, 50V, Electrolytic capacitor 9 1 C9 10 1 D1 11 1 D3 1000 pF, Y1 safety capacitor 1N4007GP 1N4007GP, 1000V, 1A, glass passivated diode trr = 2 µS (typical) SB540 SB540, 40V 5A Schottky diode 12 1 D4 BZX79 BZX79 4.3V, 4.3V, 2%, 0.5 W, Zener diode 13 1 D5 Zener diode option for over voltage protection 14 1 D6 BAV20 BAV20, small signal diode, 200V, 200mA 15 1 D8 P6KE180A P6KE180A, TVS zener, 5W, 180V, 5% 16 1 L1 3.3 µH, 3A, Ferrite drum core inductor, # 22 AWG magnet wire 17 2 R1, R6 10 , 1/4W, 5%, resistor 18 1 R2 16 K, 1/4W, 5%, resistor 19 1 R3 0 , 1/8W, 5%, resistor 20 1 R4 30 , 1/4W, 5%, resistor 21 1 R5 360 , 1/8W, resistor 22 1 T1 Transformer EE19 core 23 1 U1 TNY268P TNY268P 24 1 U2 PC817D PC817D, Optocoupler Table 2 ­ Bill of Materials Page 8 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 6 Transformer 6.1 Transformer Winding 1 W4,Primary-2, 33T,#31 FL 8 FL W1,Primary-1, 66T,#31 W3,Secondary, 5T,#27x3 (TIW) 2 7 3 W2,Bias, 12T,#35 4 Figure 5 ­ Transformer Winding Note: 1. W1 and W2 are interleaved primary winding. Both flying leads (FL) should be soldered together and wrap with tape for insulation. 6.2 Electrical Specifications Electrical Strength 60Hz 1minute, from Pins 1-4 to Pins 7-8 3 kV for 1 minute Primary Inductance (Pin 1 to Pin 2) All windings open 1.12 mH ­ 1.18 mH ­ 1.24 mH Resonant Frequency All windings open 300 kHz min. Primary Leakage Inductance L12 with pins 3-8 shorted 25 µH max. Table 3 ­ Transformer Electrical Parameters Page 9 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 6.3 15W PC Standby power supply February 4, 2004 Transformer Construction Pins 5-8 Pins 1-4 W4-start(FL) W3-finish(P7) W4-finish(P1) W3-start(P8) W2-start(P3) 0.338",2mils Insulation Tape, 1 layer 3 places, 2 layer 3 places, 3 layer 2 places W2-finish(P4) W1-finish(FL) W1-start(P2) Figure 6 ­ Transformer Construction 6.4 Materials Item Description 2 2 2 [1] Core: EE19, Gapped for AL = 114 nH/T - 120 nH/T - 127 nH/T [2] Bobbin: Horizontal 8 pins [3] Magnet Wire: # 31 AWG [4] Magnet Wire: # 35 AWG [5] Triple Insulated Wire # 27 AWG [6] Tape: 3M 1298 Polyester Film (white) 0.338" x 2 mils [7] Tape: 3M 1298 Polyester Film (white) 0.135" x 2 mils (to wrap the core together) [8] Varnish Table 4 ­ Transformer BOM Page 10 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 6.5 Winding Instructions All windings should be wound in the forward direction. Bobbin orientation Place the bobbin on the winding machine with pins 1-4 on the right side and pins 5-8 on the left side. W1 (Primary winding-1) Wind 66 turns in 2 layers with # 31 AWG magnet wire ­ first layer 33T from right to left starting from pin 2 ­ 3 layers of insulation tape ­ second layer 33T from left to right and finish as flying lead. Basic Insulation 3 layers of tape for insulation. W2 (Bias winding) Wind 12 turns in one layer from left to right with # 35 AWG magnet wire starting temporarily from pin 6 and finish at pin 4, wind evenly across the width of the bobbin ­ one layer of tape ­ bring the starting end from pin 6 to pin 3. Basic Insulation 2 layers of tape for insulation. W3 (5V Winding) Wind 5 turns in one layer from left to right with # 27 x 3 (trifilar) triple insulated wire, starting from pin 8 ­ one layer of tape ­ and finish at pin 7. Basic Insulation 2 layers of tape for insulation. W4 (Primary winding-2) Wind 33 turns in one layer with # 31 AWG magnet wire from left to right starting temporarily from pin 8 and finishing at pin 1 ­ one layer of tape ­ bring the starting end from pin 8 and terminate as flying lead. Twist the flying leads (W1 and W4 FLs) together. Outer Insulation 2 layers of tape for insulation. Core Assembly Assemble and secure core halves. Final Assembly Impregnate transformer uniformly with varnish. 6.6 Design Notes: Power Integrations Device TNY268P TNY268P Frequency of Operation 132 KHz Mode Continuous/ discontinuous Peak Current 0.55 A Reflected Voltage (Secondary to Primary) 109 V Maximum AC Input Voltage 301 Vac Minimum AC Input Voltage 85 Vac Table 5 ­ Power Supply Design Parameters Page 11 of 20 Power Integrations Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com DER-11 DER-11 15W PC Standby power supply February 4, 2004 7 Transformer Design Spread Sheet ACDC_TNYII_Rev1_1_03270 1 Copyright Power Integrations Inc. 2001 INPUT ENTER APPLICATION VARIABLES INFO OUTPUT Customer VACMIN VACMAX fL VO PO n Z 85 301 60 5 15 0.79 0.5 tC CIN 3 220 ENTER TinySwitch-II VARIABLES TNY-II Chosen Device ILIMITMIN ILIMITMAX fS UNIT Volts Volts Hertz Volts Watts Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Bridge Rectifier Conduction Time mSeconds Estimate uFarads Input Filter Capacitor Power Out 0.512 0.588 132000 Universal 15W Amps Amps Hertz TNY268 TNY268 120000 Hertz 144000 109 Hertz Volts VDS 10 Volts VD 0.5 Volts TNY268 TNY268 fSmin fSmax VOR KP Core Type Core 0.74 Page 12 of 20 115 Doubled/230V 23W TINYSwitch Minimum Current Limit TINYSwitch Maximum Current Limit TINYSwitch Switching Frequency TINYSwitch Minimum Switching Frequency (inc. jitter) TINYSwitch Maximum Switching Frequency (inc. jitter) Reflected Output Voltage TINYSwitch on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.6