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Design Example Report
Title Specification Application Author Document Number Date Revision 15W power supply using TNY268P Input: 120 - 420 Vdc Output: 5V/3A, 13V/10mA PC Standby Power Integrations Applications Department DER-11 February 4, 2004 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 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
15W PC Standby power supply
February 4, 2004
Table Of Contents
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 1 2 3 4 5 6
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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 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 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.
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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 120-420Vdc (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
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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 Output Ripple Voltage 2 Output Current 2 Continuous Output Power Efficiency Ambient Temperature Symbol VIN VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 POUT TAMB 0 15 79 40 Min 120 4.75 5.0 Typ Max 420 5.25 50 3 Units Vdc V mV A V 130 10 mV mA W %
o
Comment
PFC Standby
5% 20 MHz Bandwidth isolated
13
20 MHz Bandwidth non-isolated
At full load Free convection, Sea level
C
Table 1 - Power Supply Specification
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DER-11
15W PC Standby power supply
February 4, 2004
3 Schematic
Figure 3 - TNY268 Flyback Converter - 15 W, 5V 3A, 13V 10 mA
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Page 6 of 20
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.
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DER-11
15W PC Standby power supply
February 4, 2004
5 Bill Of Materials
Item Qty Reference Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1
C1 C2 C3 C4 C5 C6 C7 C8 C9 D1 D3 D4 D5 D6 D8 L1 R1, R6 R2 R3 R4 R5 T1 U1 U2
0.01 F, 1KV, Ceramic capacitor, Z5U 1000 pF, 1KV, Ceramic capacitor, Z5U 0.1 F, 50V, Ceramic capacitor, X7R 1500 F, 10V, Electrolytic capacitor Low ESR, (Rubycon ZL series or equivalent) 1000 F, 10V, Electrolytic capacitor Low ESR, (Rubycon ZL series or equivalent) 470 F, 10V, Electrolytic capacitor Low ESR, (Rubycon ZL series or equivalent) 470 pF, 50V, Ceramic capacitor, NPO 47 F, 50V, Electrolytic capacitor 1000 pF, Y1 safety capacitor 1N4007GP, 1000V, 1A, glass passivated diode trr = 2 S (typical) SB540, 40V 5A Schottky diode BZX79 4.3V, 4.3V, 2%, 0.5 W, Zener diode Zener diode option for over voltage protection BAV20, small signal diode, 200V, 200mA P6KE180A, TVS zener, 5W, 180V, 5% 3.3 H, 3A, Ferrite drum core inductor, # 22 AWG magnet wire 10 , 1/4W, 5%, resistor 16 K, 1/4W, 5%, resistor 0 , 1/8W, 5%, resistor 30 , 1/4W, 5%, resistor 360 , 1/8W, resistor Transformer EE19 core TNY268P PC817D, Optocoupler
Table 2 - Bill of Materials
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DER-11
15W PC Standby power supply
February 4, 2004
6 Transformer
6.1 Transformer Winding
1 W4,Primary-2, 33T,#31 FL FL W1,Primary-1, 66T,#31 2 3 W2,Bias, 12T,#35 4 7 8 W3,Secondary, 5T,#27x3 (TIW)
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 Primary Inductance (Pin 1 to Pin 2) Resonant Frequency Primary Leakage Inductance 60Hz 1minute, from Pins 1-4 to Pins 7-8 All windings open All windings open L12 with pins 3-8 shorted 3 kV for 1 minute 1.12 mH - 1.18 mH - 1.24 mH 300 kHz min. 25 H max.
Table 3 - Transformer Electrical Parameters
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DER-11
15W PC Standby power supply
February 4, 2004
6.3
Transformer Construction
Pins 5-8 Pins 1-4 W4-start(FL)
W3-finish(P7)
W4-finish(P1) W2-start(P3) W2-finish(P4) W1-finish(FL) W1-start(P2)
W3-start(P8) 0.338",2mils Insulation Tape, 1 layer 3 places, 2 layer 3 places, 3 layer 2 places
Figure 6 - Transformer Construction
6.4
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] Description Core: EE19, Gapped for AL = 114 nH/T - 120 nH/T - 127 nH/T Bobbin: Horizontal 8 pins Magnet Wire: # 31 AWG Magnet Wire: # 35 AWG Triple Insulated Wire # 27 AWG Tape: 3M 1298 Polyester Film (white) 0.338" x 2 mils Tape: 3M 1298 Polyester Film (white) 0.135" x 2 mils (to wrap the core together) Varnish Table 4 - Transformer BOM
2 2 2
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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. 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. 3 layers of tape for insulation. 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. 2 layers of tape for insulation. 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. 2 layers of tape for insulation. 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. 2 layers of tape for insulation. Assemble and secure core halves. Impregnate transformer uniformly with varnish.
W1 (Primary winding-1) Basic Insulation
W2 (Bias winding)
Basic Insulation W3 (5V Winding) Basic Insulation W4 (Primary winding-2) Outer Insulation Core Assembly Final Assembly
6.6
Design Notes:
Power Integrations Device Frequency of Operation Mode Peak Current Reflected Voltage (Secondary to Primary) Maximum AC Input Voltage Minimum AC Input Voltage TNY268P 132 KHz Continuous/ discontinuous 0.55 A 109 V 301 Vac 85 Vac
Table 5 - Power Supply Design Parameters
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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 VACMIN VACMAX fL VO PO n Z tC CIN ENTER TinySwitch-II VARIABLES TNY-II Chosen Device ILIMITMIN ILIMITMAX fS fSmin fSmax VOR VDS VD KP 85 301 60 5 15 0.79 0.5 3 220 ACDC_TNYII_Rev1_1_032701.xls: TinySwitch-II Continuous/Discontinuous Flyback Transformer Design Spreadsheet Customer Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor Bridge Rectifier Conduction Time mSeconds Estimate uFarads Input Filter Capacitor Volts Volts Hertz Volts Watts
INFO
OUTPUT
UNIT
TNY268 TNY268 Power Out 0.512 0.588 132000 120000 144000 109 10 0.5 0.74
Universal 15W Amps Amps Hertz Hertz Hertz Volts Volts Volts
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 (0.6Core Type Core Bobbin AE LE AL BW M
ee19 EE19 EE19_BO BBIN 0.23 3.94 1250 9 0 P/N: P/N: cm^2 cm nH/T^2 mm mm PC40EE19-Z BE-19-118CPH 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)
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DER-11
L NS DC INPUT VOLTAGE PARAMETERS VMIN VMAX 3 5
15W PC Standby power supply
February 4, 2004
Number of Primary Layers Number of Secondary Turns
116 426
Volts Volts
Minimum DC Input Voltage Maximum DC Input Voltage
DMAX IAVG IP IR IRMS
0.51 0.16 0.51 0.38 0.24
Amps Amps Amps Amps
Maximum Duty Cycle Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current
LP NP ALG BM BAC ur LG BWE OD INS DIA AWG CM CMA Lumped parameters ISP ISRMS IO IRIPPLE CMS AWGS DIAS ODS
1159 99 118 2989 963 1704 0.22 27 0.27 0.05 0.22 32 64 264
uHenries Primary Inductance Primary Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Gauss Flux Density, IP (BP<3000) AC Flux Density for Core Loss Curves Gauss (0.5 X Peak to Peak) Relative Permeability of Ungapped Core mm Gap Length (Lg > 0.1 mm) mm Effective Bobbin Width Maximum Primary Wire Diameter including insulation mm Estimated Total Insulation Thickness (= 2 mm * film thickness) mm Bare conductor diameter Primary Wire Gauge (Rounded to next AWG smaller standard AWG value) Bare conductor effective area in circular Cmils mils Primary Winding Current Capacity (200 < Cmils/Amp CMA < 500)
10.15 4.74 3.00 3.67 948 20 0.81 1.80
Amps Amps Amps Amps Cmils AWG mm mm
Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire
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DER-11
15W PC Standby power supply
February 4, 2004
INSS
0.49
mm
Maximum Secondary Insulation Wall Thickness
VDRAIN PIVS
675 26
Volts Volts
Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage
8 Performance Data
The measurements were taken for the power supply in two ways: 1) As a stand-alone unit, and 2) In a PC power supply, operating in standby mode A comparison was made against the original standby power supply (TOP244P design) in the PC power supply. The measurements as stand-alone unit are given in the table below. 13V output is not loaded.
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DER-11
15W PC Standby power supply
February 4, 2004
8.1 Light Load Input and Output Power Comparison These measurements were taken of the whole PSU, in standby mode. A comparison is made with the original standby design, against the TinySwitch-II design. For the measurements, the original standby supply was removed and the TinySwitch-II prototype was wired in. In both cases, the standby supply was powering the primary-side 13V circuits in the PSU.
2.4 2 1.6 1.2 0.8 Original_115Vac 0.4 0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 Output Power (W) TNY268P_115Vac
Input Power (W)
Figure 7 - Input vs. Output power at 115 Vac
2.4 2 Input Power (W) 1.6 1.2 0.8 Original_230Vac 0.4 0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 TNY268P_230Vac
Output Power (W)
Figure 8 - Input vs. Output power at 230 Vac
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DER-11
15W PC Standby power supply
February 4, 2004
8.2 Efficiency comparison, standalone The efficiency of the TNY268P design is % higher than the TOP244P design, especially at light load.
90.00 80.00 70.00
Efficiency (%)
60.00 50.00 40.00 30.00 20.00 0 0.5 1 1.5
Output Current (A)
Original_115Vac TNY268P_115Vac
2
2.5
3
Figure 9 - Efficiency versus output current at 115 Vac
90.00 80.00 70.00 Efficiency (%) 60.00 50.00 40.00 30.00 20.00 0 0.5 1 1.5 Output Current (A) 2 2.5 3 Original_230Vac TNY268P_230Vac
Figure 10 - Efficiency versus output current at 230 Vac
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DER-11
15W PC Standby power supply
February 4, 2004
9 Output Ripple Measurements
9.1 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 11 and Figure 12. 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 11 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 12 - 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-11 9.2
15W PC Standby power supply
February 4, 2004
Output Voltage Ripple
Figure 13 - 5V Output Voltage Ripple at VIN = 115 Vac, I5V = 3 A
10 Revision History
Date February 4, 2004 Author MJ Revision 1.0 Description & changes Initial release Reviewed VC/AM
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DER-11
15W PC Standby power supply
February 4, 2004
Notes
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DER-11
15W PC Standby power supply
February 4, 2004
For the latest updates, visit our Web site: www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein, nor does it convey any license under its patent rights or the rights of others. 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, and EcoSmart are registered trademarks of Power Integrations, Inc. PI Expert and DPA-Switch are trademarks of Power Integrations, Inc. (c) Copyright 2003, Power Integrations, Inc.
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