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Title
Engineering Prototype Report - 3 W Universal Input TinySwitch(R)-II TNY264 Power Supply
Specification 3 W, (9 V, 0.33 A), 85-265 VAC input Target Applications Author Doc Num. Date Revision
Features
* * * * * * * * * * * * Cost effective (minimum parts count and single sided PC board) Low Cost EF12.6 transformer (132 kHz operation) Compact design: 2.0" x 1.2" x 0.75" No-load consumption < 250mW (230 VAC) Auto-restart function limits overload output power Short circuit protected Built-in circuitry practically eliminates audible noise (standard varnished transformer) ON/OFF control allows simple Zener reference and eliminates the need for loop compensation No-load regulation achieved without preload resistor Low EMI due to frequency jittering: meets CISPR22B with output capacitively grounded Optional under-voltage detect eliminates power-up glitches Hysteretic thermal shutdown: Protects power supply and automatically recovers when fault is removed
AC Adapters (cordless phones, answering machines and other consumer products) Power Integrations Applications Dept. EPR-000014 22 Feb 2002 1.3
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-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
Table of Contents
Introduction ................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic ................................................................................................................... 5 Description.................................................................................................................. 5 PCB Layout................................................................................................................. 7 Bill of Materials ........................................................................................................... 7 Transformer Specification........................................................................................... 8 7.1 Electrical Specifications .......................................................................................... 8 7.2 Materials.................................................................................................................. 8 7.3 Transformer Diagram .............................................................................................. 9 7.4 Transformer Construction ....................................................................................... 9 7.5 Transformer Sources............................................................................................... 9 8 Performance Data..................................................................................................... 10 8.1 Output Regulation ................................................................................................. 10 8.2 Efficiency............................................................................................................... 11 8.3 Standby Power Consumption ................................................................................ 11 8.4 Output Overload.................................................................................................... 12 8.5 Thermal Performance............................................................................................ 12 8.6 Conducted Emissions............................................................................................ 14 8.7 Acoustic Emissions ............................................................................................... 16 9 Waveform Scope Plots ............................................................................................. 18 9.1 Output Ripple Measurement Results .................................................................... 18 9.1.1 DC Ripple Measurement Technique .............................................................. 19 9.2 DC Output Load Transient Response ................................................................... 20 9.2.1 10% to 50% load change, 265 VAC................................................................. 20 9.2.2 10% to 100% load change, 265 VAC............................................................... 20 9.3 Turn-On Delay and Overshoot .............................................................................. 21 9.4 Drain Switching Waveforms .................................................................................. 22 9.4.1 85 VAC, Full load, 132 kHz operation.............................................................. 22 9.4.2 85 VAC, Full load, ~100 kHz operation............................................................ 22 9.4.3 265 VAC, Full load, 132 kHz operation............................................................ 23 9.4.4 265 VAC, Full load, ~60 kHz operation............................................................ 23 10 AC Surge and 100 kHz Ring Wave Immunity ........................................................... 24 10.1 Differential Mode Surge Test Results................................................................ 24 10.2 Common Mode Surge Test Results................................................................... 25 10.3 Differential Mode 100 kHz Ring Wave Test Results ......................................... 25 10.4 Common Mode 100kHz Ring Wave Test Results ............................................. 26 11 Revision History........................................................................................................ 27 Important Note: Although the EP14 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.
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1 2 3 4 5 6 7
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
1 Introduction
This document is an engineering report that describes a 9 V, 0.33 A, 3 W output and universal input power supply utilizing the TNY264P. For evaluation, a fully built and tested prototype (EP14) can be found within the Design Accelerator Kit, DAK-14. This document contains the power supply specification, schematic, bill of materials and transformer documentation. Typical operating characteristics are presented at the rear of the report and consist of performance curves, tables and waveform photos.
1.2" / 30.5 mm
2" / 51.5 mm Figure 1. EP14 Populated Circuit Board (approx. 2:1 scale)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
2 Power Supply Specification
Description Input Input Voltage Input Frequency No-load Input Power (115 VAC) No-load Input Power (230 VAC) Output Output Voltage Output Ripple Voltage Output Current Continuous Output Power Total Regulation Efficiency Environmental Conducted EMI Safety External Ambient Temperature
Symbol VIN fLINE
Min 85 47
Typ 115/230 50/60
Max 265 64 125 250 9.63 100 0.33 3.0 +2
Units VAC Hz mW mW VDC mVPK-PK A W %
Comment
VOUT VRIPPLE IOUT POUT
8.37 0 0 -2 67 71
( 7%) At output terminals 20 MHz BW
0 - 100% load 85 - 265 VAC At full load Meets CISPR22 B Designed to meet IEC950
T AMB
0
50
o
C
Natural convection
Output voltage tolerance may be improved through choice of feedback components
Table 1. Power Supply Specification
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
3 Schematic
Figure 2. EP14 Power Supply Schematic
4 Description
The EP14 is a single 9 VDC output power supply rated at 3 W. The power supply was designed to operate over an AC input range of 85-265 VAC, 47-64Hz and provides 9 VDC output with 7% accuracy to no-load. Operating efficiency is 67% worst case at full load across the entire AC line range. Compliance to CISPR22 / EN55022 Class B conducted emissions and surge immunity test level 1 (1 kV, 1.2 / 50 S - IEC1000-4-5) is achieved with minimum component count. The unit is designed to comply with international safety standards per IEC950. Minimum parts count enables a space conscious design, with outside dimensions 1.2" x 2.0" x 0.75". TinySwitch-II provides several advantages in this application. The enhanced ON/OFF control scheme allows tight regulation using a simple, low-cost secondary side Zener reference and no loop compensation. No-load regulation is achieved without a dummy load. The enhanced ON/OFF control scheme dynamically alters the internal current limit as load requirements dictate. This approach reduces cycle skipping when the core flux density is high; thus minimizing acoustic noise. This eliminates the need for special construction, the transformer merely needs to be dip varnished. Increased operating frequency (132 kHz) allows the use of a small EF12.6 core, while frequency jittering reduces conducted emissions and resulting filtering requirements. These features, combined with primary-side transformer shielding, allows EP14 to comply with CISPR22 B (FCC Class B) emissions without the use of a large, expensive
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
common mode input choke. Class B emissions are achieved for applications requiring an `artificial hand' tied to secondary return; which makes this design fully compliant with handheld applications. Standby power consumption is below 250 mW at 230 VAC input. TinySwitch-II provides greatly reduced device tolerances and incorporates built-in hysteretic overtemperature protection. These features minimize component count while maximizing device power capability. Auto-restart functionality minimizes device thermal stresses during short-circuit conditions; providing performance similar to that available with the TOPSwitch families. A fusible, flameproof resistor (R1) is used in place of a fuse to reduce cost and increase differential mode filtering. This, combined with the filter formed by L1, C1 and C2 in addition to C5, allows the unit to meet EN55022 B (CISPR22 B) conducted emission standards. The AC input is rectified and smoothed by D1-4, C1 and C2. The resulting DC bus is applied to one end of the transformer primary. The other end of the primary is connected to the TinySwitch-II DRAIN pin. Low cost RCD clamping (R4, C3 & D6) limits the maximum DRAIN voltage to below 700 V due to transformer leakage inductance. C4 provides the local bypass for TinySwitch-II. This capacitor is kept charged during the off time of the internal MOSFET, providing the energy to supply the IC. An optional line sense resistor (R3) implements under-voltage detect. This is accomplished by sensing the DC voltage across the bulk input capacitors (C1 &C2) at power-up. TinySwitch-II is disabled until the DC voltage reaches the required level. With R3 as shown (2 M) this occurs at 100 VDC. Under-voltage detect ensures that the outputs are glitch free on power-up and power down, preventing the power supply from starting if the input voltage is too low, and stopping the supply when the output falls out of regulation on power down. TinySwitch-II will detect the absence of R3 and disable the under-voltage function if not required. The secondary is rectified by D6 and C6. Second stage output filtering consists of ferrite bead (L2) and output capacitor (C7) which eliminate high frequency switching noise and reduce output ripple below 100 mVp-p. VR2 and U2 sense the output voltage. The combined voltage drop of these two components sets the output voltage to 9 V. A 5% Zener was used giving an overall tolerance and regulation variation of 7%. Using a 3% or 2% Zener allows a more tightly controlled output voltage tolerance.
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
5 PCB Layout
Figure 3. PCB Layout (2.0 x 1.2 x 0.75")
6 Bill of Materials
Item Quantity Number 1 2 2 1 3 1 4 1 5 1 6 1 7 4 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 Value 4.7 uF, 400 V 2.2 nF, 1 kV, Z5U 0.1 uF, 50 V 2200 pF, Y1, 250 V 330 uF, 16 V, HFQ 220 uF, 25 V, NHE 1N4007 1N4937, 1 A, 600 V 11DQ06, 1.1 A, 60 V 1 mH Bead 8R2, fusible, flameproof 4.7 k, 1/8W 2 M, 1/2W 330 k, 1/2W Transformer, EF12.6 TNY264P LTV817A BZX79-C8V2, 5% Part Reference Manufacturer
C1, C2 C3 C4 C5 C6 C9 D1, D2, D3, D4 D5 D6 L1 Tokin L2 Fair-rite R1 Vitrohm R2 R3 *optional for UV detect R4 T1 Hical U1 U2 VR2
Note: assumes 5% resistors
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
7 Transformer Specification
1 96T #33 AWG (0.18 mm) 8 10T # 28 AWG (0.3 mm) TIW 5 3 2 10T 2x #33AWG (0.18 mm) 1 7.1 Electrical Specifications
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 60 Hz 1minute, from Pins 1-3 to Pins 5-8 All windings open, from Pins 1-3 All windings open, from Pins 1-3 Pins 1-3, from Pins 5-8 shorted 3000 VAC 1250 H 20% 700 kHz (Min.) < 50 H
7.2
Materials
Item [1] [2] [3] [4] [5] [6] Description Core: EF12.6, Gapped for AL of 135nH/T2 Bobbin: Hical EF12.6, 8P Magnet Wire: # 33 AWG (0.18 mm) Double Nyleze Magnet Wire: # 28 AWG (0.3 mm) Triple Insulated Tape: 3M 1298 Polyester Film (white) 7.8mm wide by 2.2 mils (0.06mm) thick Varnish
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
7.3
Transformer Diagram 5 8 2 1 1 Shield Tape Secondary Tape
3
Primary
7.4
Transformer Construction
Primary Layer Insulation Shield Winding Insulation Secondary Winding Final Assembly Start at Pin 3. Wind 33 turns of item [3] from left to right. Wind 33 turns in the next layer from right to left. Wind remaining 30 turns in the next layer from left to right. Finish on Pin 1. 1 Layer of tape [5] for insulation. Continue at Pin 1. Wind 10 turns of bifilar item [3] from left to right. Wind uniformly, in a single layer, across entire width of bobbin. Finish on Pin 2. 1 Layers of tape [5] for insulation. Start at Pin 8. Wind 10 turns of item [4] from right to left. Wind uniformly, in a single layer, across entire width of bobbin. Finish on Pin 5. Assemble and secure core halves. Impregnate uniformly (dip varnish) [6] and bake.
7.5 Transformer Sources For information on the vendors used to source the transformer, please visit our website at the address below and select Engineering Prototype Boards http://www.powerint.com/componentsuppliers.htm
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
8 Performance Data
Performance data was collected on a single prototype unit (UUT2) at room temperature, unless specified otherwise. Testing was done using a programmable AC generator, Kikusui PLZ-72W electronic load and high resolution AC wattmeter. Details of the test set-up are available in the individual sections. 8.1 Output Regulation AC source set at 50 Hz with a DC load and a DC ammeter. DC regulation data represents the deviation on the output channel across the full load range (no load - 0 A, 1/2 load - 0.17 A and full load - 0.33 A) and while varying AC input (85 - 265 VAC). Output voltage transitions may occur when shifting between operating modes; producing a slight deviation to the curve fit presented.
Output Load Regulation
2.50%
Output Deviation (%)
2.00%
85/115VAC
1.50%
230/265VAC
1.00%
0.50%
0.00% 0 0.1 0.2 0.3
Output Current (A)
Figure 4. Output Load Regulation vs AC Line Voltage
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
8.2 Efficiency Efficiency data was collected at full load while varying the AC input, 50 Hz line frequency. Thermal stabilization was verified. Data represents worst-case efficiency in high frequency operating mode. Due to capacitive switching losses, high voltage efficiency is reduced in high frequency mode (132 kHz).
Efficiency
78.0% 76.0%
Efficiency (%)
74.0% 72.0% 70.0% 68.0%
85
135
185
Input Voltage (VAC)
235
Figure 5. Supply Efficiency vs Line Voltage
8.3 Standby Power Consumption Standby power was measured with output load disconnected utilizing a high resolution AC wattmeter after the supply had thermally stabilized
Standby Power Loss
0.25
0.2
Dissipation (W)
0.15
0.1
0.05
0 75 95 115 135 155 175 195 215 235 255 275
Input VAC
Figure 6. Supply Standby Power vs Line Voltage
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
8.4 Output Overload The following curve shows results with the output overload, at room ambient. Output load was adjusted to obtain maximum continuous output current while varying the AC line input. The power supply will operate in auto-restart mode when maximum output current is exceeded. A reduction in maximum output current and input power can be expected as operating temperature is increased.
Maximum Output Current vs AC Input
0.9 0.8 Output Current (A) 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 85 120 200 VAC Input 230 265 IOUT max PIN 12 10 8 6 4 2 0 Input Power (W)
Figure 7. Maximum Output Current vs Line Voltage
8.5 Thermal Performance Thermal data was collected at room temperature and raised ambient with natural convection, no power supply enclosure, and at a full load of 3 W with the AC line varied. All temperatures were recorded with T-type thermocouples and represent the temperature rise over power supply external ambient, in degrees Celsius (+C).
* * * * * Transformer measured on core, outer leg (glued between core leg and output windings) TNY264P soldered to Source lead (pin 2) All other thermocouples glued to component body Local power supply ambient air temperature was monitored The following data represents worst-case dissipation, operating at 132 kHz mode(s)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
VAC 85 115 230 265 85 265
DAK-14 Component Temperature Rise (+C) T1 L1 PIN (W) TAMB TNY264P core inductor 4.08 25 34.9 26.7 9.5 4.01 25 32.1 26.0 8.9 4.16 25 39.9 28.3 9.5 4.27 25 47.8 31.7 10.2 4.16 50 34.7 21.8 9.8 4.35 50 46.2 27.7 10.0
Table 2. Key Component Thermal Rise Data
C4 capacitor 16.9 17.6 18.7 19.1 16.1 17.5
Figure 8. Infra Red Scan of DAK-14, 25 C Ambient
These results indicate that this is an optimum thermal design. The TNY264 is the hottest component with a 46 C rise above ambient. This gives an acceptable device temperature of ~100 C at an external ambient of 50 C.
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
8.6 Conducted Emissions The following conducted emissions scans were recorded operating at full load (resistive 3 W), 115/230 VAC, 60 Hz. A two-wire AC cord was used. In all cases the `artificial hand' connection of the LISN was tied to secondary side RTN. The worst-case phase was recorded (conducted emissions on alternate phase typically varies 1-2 dBV). Rohde & Schwarz Model ESPC receiver and LISN Model ESH3-Z5. In all cases it was verified that the TNY264 operated at full frequency (132 kHz), to ensure worst-case results. Line emissions were measured across the frequency range. Pre-scan sweeps for each detector type are presented, Quasi-Peak (top / blue) and Average (bottom / green). Limit lines for CISPR 22 (EN55022) Class B Quasi-Peak (top / red) and Average (bottom / magenta) are visible. Any peak within 15 dB of the limit line was verified with a 1sec measurement. These results are shown on the scans (Figures 9 & 10) as a red cross (x) or a magenta plus (+).
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
QP Limit AV Limit
Quasi Peak
Average
Figure 9. Conducted Emissions, 115 VAC Line
QP Limit AV Limit
Quasi Peak
Average
Figure 10. Conducted Emissions, 230 VAC Line
A 2-3 dBV reduction in broadband emissions is obtained with the `artificial hand' disconnected. Increased emissions can be expected with secondary RTN tied to the LISN ground connection (PE).
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
8.7 Acoustic Emissions The power supply was subjected to acoustic emissions measurement. The worst-case noise was measured for variations of both AC line and output loading conditions. These results are presented in Figure 12 and Figure 13. In all cases, acoustic emissions were below acceptable levels. The test unit was placed in an anechoic acoustic chamber, with a microphone located approximately 1" (25 mm) above the transformer (T1) as shown in Figure 11. The power supply was oriented in a horizontal position with the power supply output loaded via an external Kikusui electronic load. The microphone output was fed to an Audio Precision audio analyser to provide the measurements shown. Microphone
Figure 11. Test Arrangement for Audio Noise Measurement
The curves shown indicate the spectral content of the noise generated by the supply once the ANSI-A weighting factor has been applied. The audio limit line (Figure 12, 13) visible at +35 dB represents the generally accepted threshold for power supply audio noise. A discrete audio frequency amplitude was used rather than a dBA value (dBA represents the whole audio spectrum). Large peaks may not raise the dBA value yet can result in unacceptable perceived noise. As a reference, the approximate dBA background noise floor level is 30 dBA. The microphone sensitivity is such that 20 P = 0 dB SPL.
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
Up to a further 20 dB reduction can be expected, from the measurement shown, once the power supply is sealed inside an enclosure.
Figure 12. Acoustic Emissions Spectrum, 230 VAC Input, 9 V, 0.21 A Output
Figure 13. Acoustic Emissions Spectrum, 230 VAC Input, 9 V, 0 A Output
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
9 Waveform Scope Plots
The following bench data was collected with a Yokogawa DL1540L oscilloscope, Kikusui electronic load and at an AC input frequency of 50 Hz. 9.1 Output Ripple Measurement Results Output ripple measurement at worst-case 265 VAC is presented across the loading range, 20 MHz oscilloscope bandwidth. In all cases, output ripple is maintained below 100 mVp-p. See Figure 15 for details of scope probe. The output ripple waveshape is a function of AC input voltage and load and may vary with the TNY264 operating mode.
VOUT_AC Load: 0% / 0 A VOUT_AC Load: 50% / 0.17 A VOUT_AC Load: 100% / 0.33 A
Figure 14. Output Ripple (265 VAC, 0 A, 0.17 A & 0.33 A Loading, 50 mV/div)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
9.1.1 DC Ripple Measurement Technique Details of output ripple probe are provided below. Decoupling capacitors are included to minimize the effects of high frequency probe coupling and ensure a consistent measurement setup. Probe RTN
Probe Tip
Figure 15. Tektronix P6105A Oscilloscope Probe with Probe Master 5125BA BNC adapter, modified with wires for Probe Ground for ripple measurement. Two parallel decoupling capacitors have been added (1.0 F, 50 V aluminum electrolytic and a 0.1 F, 50 V ceramic)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
9.2 DC Output Load Transient Response Worst case transient measurements were obtained with a Kikusui electronic load and a Yokogawa DL1540L oscilloscope (20 MHz bandwidth) during output load steps at 265 VAC. The transient response exhibits negligible overshoot. 9.2.1 10% to 50% load change, 265 VAC
VOUT_AC
IOUT
Figure 16. Transient Response 265 VAC 50 Hz, IOUT: 0.03 A to 0.17 A VOUT & IOUT (100 mV & 200 mA/div, 2 ms/div)
9.2.2 10% to 100% load change, 265 VAC
VOUT_AC
IOUT
Figure 17. Transient Response 265 VAC 50 Hz, IOUT: 0.03 A to 0.33 A VOUT & IOUT (100 mV & 200 mA/div, 2 ms/div)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
9.3 Turn-On Delay and Overshoot Turn-on delay was recorded as referenced to the DRAIN-SOURCE voltage. A resistive load is recommended to avoid incorrect results when using electronic loads. In all cases, overshoot is negligible and turn-on delay is less than 8 ms, worst-case.
VOUT_DC
VDRAIN
Figure 18. Start-up, 0.33 A Load, 85 VAC VOUT & VDRAIN (5 & 200 V/div, 2ms/div)
VOUT_DC
VDRAIN
Figure 19. Start-up, 0.33 A Load, 265 VAC VOUT & VDRAIN (5 & 200 V/div, 2ms/div)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
9.4 Drain Switching Waveforms The following waveforms detail DRAIN-SOURCE voltage and current at full load while varying the AC input. The operating mode of the TNY264 can vary under identical operating conditions. The waveforms display both the high and low switching frequencies possible under identical operating conditions. Actual operating mode depends on magnetizing inductance (LP), current limit (ILIM), together with line voltage and load. 9.4.1 85 VAC, Full load, 132 kHz operation
VDRAIN
IDRAIN
Figure 20. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 85 VAC Input. (5 s/div)
9.4.2 85 VAC, Full load, ~100 kHz operation
VDRAIN
IDRAIN
Figure 21. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 85 VAC Input. (5 s/div)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
9.4.3 265 VAC, Full load, 132 kHz operation
VDRAIN
IDRAIN
Figure 22. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 265 VAC Input. (5 s/div)
9.4.4 265 VAC, Full load, ~60 kHz operation
VDRAIN
IDRAIN
Figure 23. VDRAIN & IDRAIN (200 V & 0.1 A/div) at 3 W Load, 265 VAC Input. (5 s/div)
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
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10 AC Surge and 100 kHz Ring Wave Immunity
Running at full load (resistive 3 W), 115 and 230 VAC, 60 Hz. the power supply was subjected to repeated high voltage AC Surge (IEC 1000-4-5) and Ring Wave tests (IEEE C62.41). These included both common mode and differential mode injection. A Keytek EMCPro was utilized with a 2 /12 source impedance (as indicated). In typical adapter applications immunity to 1 kV (IEC 1000-4-5, class 2) would be required. From the results below it can be seen that this is exceeded. To monitor power supply status, LED were connected across the DC output. Evaluation was completed with reference to the following: Pass Blink Latch-up Fail Normal performance within specification limits Temporary degradation (PSU glitches - LED blink) Temporary degradation with operator intervention (PSU stops - LED turns off, but returns with AC cycle) Permanent, unrecoverable degradation (power supply and/or component damage)
Conditions were a single sample (UUT4) with tests performed in the order indicated. Corrective action between test failures were as indicated. The environmental conditions were a room ambient of 23 C with ~70 % humidity, a repetition rate 1of 5 s, an internal trigger and 90 phase injection. 10.1 Differential Mode Surge Test Results The results for differential mode surge immunity testing are shown below (IEC 1000-4-5, 1.2/50 s - 8/20 s, L-N). For differential mode tests, a two-wire AC cord was utilized. AC Ground (PE) was disconnected. There was a 2 generator source impedance. Compliance beyond Class 3 (1 kV), with no degradation, was confirmed.
Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 -2000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass n/a 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Fail n/a Test Sequence 1 2 3 4 5 6 7 8
Table 3. Differential Mode Surge Test Results
Differential Surge failure at +2 kV required replacement of input fusible resistor (R1), TNY264P (U1) and transformer (T1). Testing was completed on UUT4.
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EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
10.2 Common Mode Surge Test Results The results for common mode surge immunity testing are shown below (IEC 1000-4-5, 1.2/50 s - 8/20 s, L/N-G). For common mode tests, a three-wire AC cord was utilized. AC Ground (PE) was tied from AC outlet to power supply output RTN through a copper strap. There was a 2 generator source impedance. Compliance beyond Class 3 (2 kV), with no degradation, was confirmed.
Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 +2000 +3000 -3000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Test Sequence 1 2 3 4 5 6 7 8 9 10
Table 4. Common Mode Surge Testing Results
Y-capacitor verified prior to proceeding with immunity testing. 10.3 Differential Mode 100 kHz Ring Wave Test Results The results for differential mode 100 kHz Ring Wave immunity testing are shown below (IEEE C62.41, L-N). For differential mode tests, a two-wire AC cord was utilized. AC Ground (PE) was disconnected. There was a 12 generator source impedance. Compliance to 3 kV, with no degradation, was confirmed.
Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 +2000 +3000 -3000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Test Sequence 1 2 3 4 5 6 7 8 9 10
Table 5. Differential Mode 100 kHz Ring Wave Test Results
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Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
10.4 Common Mode 100kHz Ring Wave Test Results The results for common mode 100 kHz Ring Wave immunity testing are shown below (IEEE C62.41, L/N-PE). For common mode tests, a two wire AC cord was utilized. AC Ground (PE) was tied from AC outlet to power supply RTN through a copper strap. There was a 12 generator source impedance. Compliance to 3 kV, with no degradation, was confirmed.
Iteration Voltage (VAC) +500 -500 +1000 -1000 +1500 -1500 +2000 +2000 +3000 -3000 1 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 2 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 3 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 4 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass 5 115/230 Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Pass/Pass Test Sequence 1 2 3 4 5 6 7 8 9 10
Table 6. Common Mode 100 kHz Ring Wave Test Results
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 26 of 28
22-Feb-2002
EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
11 Revision History
Date 09-Feb-2001 21-Feb-2001 26-Feb-2001 15-Mar-2001 20-Mar-2001 02-Apr-2001 22-Feb-2002 Author SH SH SH SH PV PV PV Revision 0.1 0.2 0.3 1.0 1.1 1.2 1.3 Description & changes Original draft Update new transformer results Format changes, rev thermal results Format changes Format changes - audio noise set photo added Spelling and formatting errors corrected p.6 - reference to D6 corrected to read D5 in fourth paragraph
Page 27 of 28
Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
EPR-000014 - 9 V, 0.33 A, 3 W TNY264 Adapter
22-Feb-2002
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, 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
NORTH AMERICA - EAST & SOUTH AMERICA Power Integrations, Inc. Eastern Area Sales Office 1343 Canton Road, Suite C1 Marietta, GA 30066 USA Phone: +1*770*424*5152 Fax: +1*770*424*6567
EUROPE & AFRICA Power Integrations (Europe) Ltd. Centennial Court Easthampstead Road Bracknell Berkshire RG12 1YQ, United Kingdom Phone: +44*1344*462*300 Fax: +44*1344*311*732 JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama 2Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222, Japan Phone: +81*45*471*1021 Fax: +81*45*471*371
TAIWAN Power Integrations International Holdings, Inc. 2F, #508, Chung Hsiao E. Rd., Sec. 5, Taipei 105, Taiwan Phone: +886*2*2727*1221 Fax: +886*2*2727*1223
CHINA Power Integrations, China Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu Shenzhen Guangdong, 518031 Phone: +86*755*377*9485 Fax: +86*755*377*9610
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
INDIA (Technical Support) Innovatech #1, 8th Main Road Vasanthnagar Bangalore 560052, India Phone: +91*80*226*6023 Fax: +91*80*228*9727
APPLICATIONS HOTLINE World Wide +1*408*414*9660
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Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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