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| Design Idea DI-77 (R) TinySwitch-II 3 W Adapter: Application Adapter Device TNY263P Power Output 3W <200 mW No-Load Consumption Input Voltage 85-265 VAC Output Voltage 9 V / 330 mA Topology Flyback Design Highlights * * * * * * Replaces a linear transformer based power supply at the same or lower cost, but with much higher performance <200 mW no-load consumption (at 115/230 VAC) Meets CISPR 22-B with >15 dB margin, w/o Y capacitor Low cost, low component count solution: only 24 parts! TinySwitch-II On/Off regulation scheme produces 5% output regulation over temperature with a 2% Zener Does not require a transformer bias winding (a similarly rated linear transformer adapter will typically consume approximately 1 W under no-load). This low no-load consumption is the result of the inherent cycle skipping feature of the TinySwitch-II and careful transformer design. Key Design Points * Minimize secondary-side power consumption. Zener diode VR1 receives its bias current from the opto-LED in U2. Using a low current device minimizes consumption while providing an output voltage tolerance of 5%. A TL431 can be used for tighter output voltage accuracy. Minimize clamp losses: design the transformer to have a low reflected voltage (VOR). In this case, VOR was set to 90 V. Minimize leakage inductance: select wire gauge sizes that completely fill each winding layer of the transformer. Minimize intra-winding capacitance and no-load consumption: put a layer of tape between each primary winding layer. Use >200 k resistor in the RCD clamp to further reduce power losses if the following two conditions are met: 1) the EMI performance is not compromised, and 2) there is enough drain voltage (BVDSS) margin for the internal MOSFET. R2 16 NC NC C7 1 F 50 V L3 Bead D6 11DQ06 9 V, 330 mA Operation This TinySwitch-II based flyback converter produces an isolated 3 W, 9 VDC output from an 85 VAC to 265 VAC input. Fusible resistor RF1 gives short circuit fault protection and limits startup inrush current. Inductors L1 and L2 and capacitors C1 and C2 form a low-cost pi () filter that attenuates conducted EMI. In addition, the internal frequency jitter of the TinySwitch-II, the use of shield windings, an output RC snubber, and a primaryside RCD clamp makes the circuit meet CISPR-22 Class B conducted EMI limits without a Y capacitor, resulting in a very low value of AC leakage current (<300 A). The key performance characteristic of this circuit is the extremely low no-load power consumption of <200 mW L2 Bead R1 200 k 1/2 W C3 1 nF 1 kV RF1 8.2 1.0 W D1 1N4007 D2 1N4007 C1 4.7 F 400 V R3 200 D5 1N4007G C2 4.7 F 400 V D * * * * 1 10 3 T1 EE16 Lp = 1.6 mH 8 C5 330 F 16 V C6 100 F 25 V L 85 - 265 VAC RTN VR1 BZX79-B8V2 N TinySwitch-II U1 TNY263P EN BP D3 1N4007 D4 1N4007 U2 PC817A C4 0.1 F 50 V PI-3877-060404 S L1 1.0 mH Figure 1. TinySwitch-II 3.0 W Adapter. DI-77 www.powerint.com May 2004 DI-77 PI-3878-051204 TRANSFORMER PARAMETERS Output Voltage (VDC) 10.0 9.5 9.0 8.5 8.0 7.5 7.0 6.5 6 0 50 85 VAC 265 VAC Core Material Bobbin TDK PC40 EE16, AL = 190 nH/T2 EE16 Horizontal 10 pin Core Cancellation: 26T, 2 x 36 AWG Primary: 46T + 46T, 35 AWG Shield: 8T, 2 x 26 AWG Secondary: 10T, T.I.W. 24 AWG Core Cancellation (1-NC), 2 x Tape, Primary (3-1), Tape, Shield (2-NC), 2 x Tape, Secondary (10-8) 1.60 mH 10% Winding Details Winding Order (pin numbers) Primary Inductance 100 150 200 250 300 350 Output Current (mA) Figure 3. Load Regulation-CV Characteristics. 300 50 H (maximum) Power Consumption (mW) Leakage Inductance 250 200 150 100 50 0 Table 1. Transformer Design Parameters. PI-3880-051204 80 70 60 50 40 QP AV Quasi Peak dBV 30 20 10 0 -10 -20 0.15 1.0 10.0 -100.0 Average 80 130 180 230 280 Input Voltage (VAC) Figure 4. No-Load Input Power Variation with Input Voltage. MHz Figure 2. Conducted EMI, Full-Load, 230 VAC, Power Return Connected to "Artificial Hand" of LISN. For the latest updates, visit 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 LIMITATIONS, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. 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. PI Expert and DPA-Switch are trademarks of Power Integrations. Copyright 2004, Power Integrations Power Integrations MAIN PHONE NUMBER +1 408-414-9200 A 5/04 5245 Hellyer Avenue APPLICATIONS FAX +1 408-414-9760 San Jose, California 95138 For a complete listing of worldwide sales offices, please visit www.powerint.com APPLICATIONS HOTLINE +1 408-414-9660 www.powerint.com PI-3879-051204 Primary Resonant 600 kHz (minimum) Frequency |
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