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Design Example Report
Title Specification Application Author Document Number Date Revision
Summary
Dual output design featuring primary-side regulation to eliminate opto-coupler ESHIELD Transformer construction allows for simple input pi-filter and no safety X or Y capacitors o 27 total components including EMI filter o Short Circuit Protection o Hysteretic Thermal Shutdown o Frequency Jitter o Excellent Conducted EMI (>8 dB margin across spectrum) o EcoSmart Technology o Extremely low standby power consumption (<700 mW with 250 mW pre-load) o o
7.2 W Dual Output Power Supply using TNY267G Input: 90 - 265 VAC Output: 24V/150mA, 24V/150mA Network Interface Power Integrations Applications Department DER-108 October 26, 2005 1.0
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-108
Network Interface
October 26, 2005
Table Of Contents
1 2 3 4 5 6 Introduction................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 PCB Layout ................................................................................................................ 6 Bill Of Materials .......................................................................................................... 7 Transformer Specification........................................................................................... 8 6.1 Electrical Diagram ............................................................................................... 8 6.2 Electrical Specifications....................................................................................... 8 6.3 Materials.............................................................................................................. 8 6.4 Transformer Build Diagram ................................................................................. 9 6.5 Transformer Construction.................................................................................... 9 7 Transformer Spreadsheets....................................................................................... 10 8 Performance Data .................................................................................................... 12 8.1 Efficiency........................................................................................................... 12 8.2 No-load Input Power.......................................................................................... 12 8.3 Regulation ......................................................................................................... 13 9 Waveforms ............................................................................................................... 14 9.1 Drain Voltage and Current, Normal Operation .................................................. 14 9.2 Output Voltage Start-up Profile ......................................................................... 14 9.3 Output Ripple Measurements............................................................................ 15 9.3.1 Ripple Measurement Technique ................................................................ 15 9.3.2 Measurement Results ................................................................................ 16 10 Conducted EMI ..................................................................................................... 17 11 Revision History .................................................................................................... 18
Important Notes: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolated source to provide power to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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DER-108
Network Interface
October 26, 2005
1 Introduction
This document is an engineering report describing a dual output power supply utilizing a TNY267G. This power supply is intended as a bias power supply. 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-108
Network Interface
October 26, 2005
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Total Output Power Continuous Output Power Efficiency Environmental Conducted EMI Safety Surge
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Symbol VIN fLINE
Min 90 47
Typ
Max 265 64 1 28.2
Units VAC Hz W V mV A V mV A
Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2
19.2
24 500 0.15 24 500 0.15
20% 20 MHz bandwidth
19.2
28.2
20% 20 MHz bandwidth
POUT
7.2 72
W %
Measured at POUT (7.2 W), 25 oC
TBD
kV
Surge Ambient Temperature TAMB 0
TBD 40
kV
o
1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: 12 100 kHz ring wave, 500 A short circuit current, differential and common mode Free convection, sea level
C
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DER-108
Network Interface
October 26, 2005
3 Schematic
Figure 2 - Schematic
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October 26, 2005
4 PCB Layout
Figure 3 - Printed Circuit Layout
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DER-108
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October 26, 2005
5 Bill Of Materials
Item QTY Ref. Des. Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 2 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 BR1 C1 C2 C3 C7 C9 C4 C5 C6 D5 D6 D7 D8 L1 Q1 R2 R3 R4 R5 R6 R7 R8 R9 RF1 T1 U1 VR1 600 V, 1 A, Bridge Rectifier, SMD, DFS 10 uF, 400 V, Electrolytic, Low ESR, 2.9 Ohms, (10 x 20) 100 nF, 50 V, Ceramic, X7R, 0805 2.2 nF, 1 kV, Disc Ceramic 200 V, 0.2 A, Fast Switching, 50 ns, SOD-323 200 V, 2 A, Ultrafast Recovery, 20 ns, DO-214AA 1 mH, 0.15 A, Ferrite Core NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 100 R, 1%, 1/4 W, Metal Film, 1206 510 R, 5%, 1/8 W, Metal Film, 0805 75 R, 5%, 1/8 W, Metal Film, 0805 150 k, 5%, 1 W, Metal Oxide 4.7 k, 5%, 1/4 W, Metal Film, 1206 10 R, 1%, 1/4 W, Metal Film, 1206 24 k, 5%, 1/8 W, Metal Film, 0805 8.2 R, 2.5 W, Fusible/Flame Proof Wire Wound Bobbin, EE16, Vertical, 10 pins TinySwitch-II, TNY267G, SMD-8B 27 V, 5%, 500 mW, DO-213AA (MELF) Power Integrations Diodes Inc TNY267G ZMM5254B-7
Mfg
Vishay United Chemi-Con Panasonic
Mfg Part Number
KMX400VB10RM10X20L L ECU-V1H221KBN KZE35VB221MH15LL DL4007 BAV21WS-7-F ES2D SBCP-47HY102B MMBT3904 ERJ-8ENF1000V ERJ-6GEYJ511V ERJ-6GEYJ750V RSF100JB-150K ERJ-8GEYJ472V ERJ-8ENF10R0V ERJ-6GEYJ243V CRF253-4 5T 8R2
220 uF, 35 V, Electrolytic, Very Low ESR, 56 mOhm, (8 x 15) United Chemi-Con 1000 V, 1 A, Rectifier, Glass Passivated, DO-213AA (MELF) Diodes Inc Diode Inc. Diodes Inc Tokin Vishay Panasonic Panasonic Panasonic Yageo Panasonic Panasonic Panasonic Vitrohm
NIC Components Corp NCD222K1KVY5F
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Network Interface
October 26, 2005
6 Transformer Specification
Note: Winding the bias winding after the secondary winding (using triple insulated wire) will result in better load regulation. 6.1 Electrical Diagram
Figure 4 - Transformer Electrical Diagram
6.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-4 to Pins 5-8 Pins 1-2, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with Pins 5-8 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 855H, -0/+20% 800 kHz (Min.) 35 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
6.3
Materials
Description Core: EE16 ALG=140nH/T Bobbin: 8-pin bobbin Magnet Wire: #34 Heavy Nyleze Magnet Wire: #32 Heavy Nyleze Triple Insulated Wire: #30 TEX-E Tape, 3M Varnish
2
Item [1] [2] [3] [4] [5] [6] [7]
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DER-108 6.4
Network Interface
October 26, 2005
Transformer Build Diagram
Figure 5 - Transformer Build Diagram
6.5
Transformer Construction
Shield Winding 1 Basic Insulation Primary Basic Insulation Bias Winding Basic Insulation Shield Winding 2 Reinforced Insulation Secondary Winding Basic Insulation Secondary Winding Outer Wrap Final Assembly
Start on pin1 and wind 22 turns (x 2 filar) of item [3] in exactly 1 layer. Leave this end of cancellation shield winding not connected. Bend the end 90 deg and cut the wire in the middle of the bobbin. Use three layers of item [6] for basic insulation. Start at Pin 2. Wind 78 turns of item [3] in approximately 3 layers, finish on Pin1. Use one layer of item [6] for basic insulation. Starting at Pin 3, wind 14 turns of item [3]. Spread turns evenly across bobbin. Finish at Pin 4. Use one layer of item [6] for basic insulation. Start temporarily on pin 8 and wind 14 turns (x 2 filar) of item [4] in exactly 1 layer. Finish winding on pin 1, cut the beginning end wire in the middle of the bobbin. Use three layers of item [6] for reinforced insulation. Start at Pin 5. Wind 16 turns of item [5] in 1 layer. Finish on Pins 6. Use one layer of item [6] for basic insulation. Start at Pin 8. Wind 16 turns of item [5] in 1 layer. Finish on Pins 7. Wrap windings with 3 layers of tape [item [6]. Assemble and secure core halves. Dip varnish cores (item [7]).
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DER-108
Network Interface
October 26, 2005
7 Transformer Spreadsheets
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October 26, 2005
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8 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 8.1 Efficiency
Figure 6 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
8.2
No-load Input Power
Figure 7 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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October 26, 2005
8.3 Regulation Note: Winding the bias winding after the secondary winding (using triple insulated wire) will result in better load regulation.
90VAC Load Current 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 v1 28.78 25.26 24.15 23.43 22.96 22.68 22.37 22.19 21.90 v2 31.03 27.33 26.09 25.38 24.83 24.50 24.17 24.01 23.67 120VAC v1 28.78 25.04 23.88 23.13 22.68 22.42 22.08 21.94 21.72 v2 31.03 27.08 25.79 25.03 24.50 24.22 23.81 23.71 23.43 132VAC v1 28.77 24.98 23.78 23.00 22.50 22.25 21.94 21.69 21.49 v2 31.02 27.02 25.69 24.90 24.31 24.03 23.66 23.45 23.20 180VAC v1 28.79 24.86 23.47 22.70 22.08 21.83 21.39 21.23 20.89 v2 31.04 26.90 25.35 24.58 23.87 23.60 23.07 22.96 22.56 240VAC v1 28.78 24.62 23.07 22.15 21.48 21.18 20.70 20.56 20.11 v2 31.03 26.64 24.92 23.99 23.25 22.91 22.36 22.26 21.74 265VAC v1 28.76 24.48 22.87 21.97 21.34 20.98 20.53 20.29 19.92 v2 31.01 26.49 24.73 23.81 23.09 22.70 22.17 21.97 21.53
Figure 8 - Line/Load Regulation Data, Room Temperature
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October 26, 2005
9
9.1
Waveforms
Drain Voltage and Current, Normal Operation
Figure 9 - 90 VAC, Full Load. Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 100 V, 5 s / div
Figure 10 - 265 VAC, Full Load Upper: IDRAIN, 0.2 A / div Lower: VDRAIN, 200 V / div
9.2
Output Voltage Start-up Profile
Figure 11 - Start-up Profile, 90VAC 5 V, 20 ms / div.
Figure 12 - Start-up Profile, 265 VAC 5 V, 20 ms / div.
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October 26, 2005
9.3
Output Ripple Measurements
9.3.1 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 13 and Figure 14. 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 13 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 14 - 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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9.3.2 Measurement Results
Figure 15 - Ripple, 120 VAC, Full Load. 1 ms, 500 mV / div
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October 26, 2005
10 Conducted EMI
Line
Neutral
Figure 16 - Conducted EMI, Maximum Steady State Load, 120 VAC, 60 Hz, and EN55022 B Limits
Line
Neutral
Figure 17 - Conducted EMI, Maximum Steady State Load, 240 VAC, 60 Hz, and EN55022 B Limits
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11 Revision History
Date 10-26-05 Author RSP Revision 1.0 Description & changes Initial Release Reviewed KM/JC/VC
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DER-108
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October 26, 2005
For the latest updates, visit our website: www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NONINFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, EcoSmart, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)Copyright 2005 Power Integrations, Inc.
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