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Design Example Report
Title Specification Application Author Document Number Date Revision 3.5W CV/CC Adapter using TNY264P Input: 90 - 265 VAC Output: 5.5V /0.65A Cell Phone Charger Power Integrations Applications Department DER-35 April 5, 2004 1.0
Summary and Features This document is an engineering report describing a cell phone charger power supply utilizing a TNY264P, with the following features: * * * * * Low cost No Y-cap Meets EMI Very Low Leakage Current Does not require a TL431
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-35
Cell Phone Adapter TNY264
April 5, 2004
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 ............................................................................................. 13 8.3 Output Characteristic. ........................................................................................... 13 8.4 Line Regulation..................................................................................................... 14 9 Thermal Performance............................................................................................... 15 10 Waveforms ............................................................................................................... 16 10.1 Drain Voltage and Current, Normal Operation .................................................. 16 10.2 Output Voltage Start-up Profile ......................................................................... 16 10.3 Drain Voltage and Current Start-up Profile........................................................ 17 10.4 Load Transient Response (75% to 100% Load Step) ....................................... 17 10.5 Out put Ripple Measurements........................................................................... 18 10.5.1 Ripple Measurement Technique.................................................................... 18 10.5.2 Measurement Results.................................................................................... 19 11 Conducted EMI......................................................................................................... 20 12 Revision History ....................................................................................................... 21
Important Note: 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 isolation transformer to provide the AC input 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.
Page 2 of 22
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-35
Cell Phone Adapter TNY264
April 5, 2004
1 Introduction
This document is an engineering report describing a cell phone charger power supply utilizing a TNY264P. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
Figure 1 - Populated Circuit Board Photograph.
Page 3 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
2 Power Supply Specification
Description Input Voltage Frequency Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Efficiency Environmental Conducted EMI Safety Ambient Temperature TAMB
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Symbol VIN fLINE VOUT1 VRIPPLE1 IOUT1 POUT
Min 90 47 5.1 600
Typ
Max
Units VAC Hz V mV mA W %
Comment
2 Wire - no P.E.
115/230 264 50/60 63 5.4 5.7 100 720
when in CV Mode 20 MHz Bandwidth when in CC mode
3.5 55
Measured at Full Load Nominal Input Voltage 25 oC
0
25
40
o
C
Free convection, sea level
Page 4 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
3 Schematic
Figure 2 - Schematic.
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 5 of 22
DER-35
Cell Phone Adapter TNY264
April 5, 2004
4 PCB Layout
Figure 3 Printed Circuit Layout TOP Silk Screen and Copper Bottom Layers
Figure 4 - Printed Circuit Layout. Bottom Silk Screen and Copper Bottom Layers.
Page 6 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
5 Bill Of Materials
Item Number Quantity Part 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
2 1 1 1 1 1 4 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1
C1 C2 C3 C4 C6 C7 C8 D1 D2 D3 D4 D5 D7 J1 J2 J3 J4 L1 Q1 R1 R2 R7 R8 R10 R11 R12 RF1 T1 U1 U2 VR2
Cap,Al Elect,4.7uF,400V,8mmX11.5mm,Sam Young Cap,Cer,470pF, 1000V, 10% CAP 0.1uF 50V CERM CHIP X7R 0805 SMD Cap,Al Elect,470uF,10V,8mmX11.5mm,KZE Series,NIPPON CHEMI-CON Cap,Al Elect,100uF,10V,5mmX11.5mm,LXZ Series,NIPPON CHEMICON CAP 1000pF 50V CERM CHIP X7R 0805 SMD Rectifier GPP 1000V 1A DO-41 RECT,DL4007-13 PASSIVATED 1A 1000V SMD MELF SLG41-60 DIODE SCHOTTKY,60V 1A Terminal,1Pin,18AWG CHOKE,1mH,SBCP_47HY102B,TOKIN TRANS,2N3906, PNP SS GP 200MA TO-92 Res, 200K, 1/2W, 5%, Carbon Film Res,100 1/10W 5% 0805 SMD Res, 1.8 ,1W, 5%, Metal Film Res,300 1/10W 5% 0805 SMD Res,5.1 1/10W 5% 0805 SMD Res,160 1/10W 5% 0805 SMD Res,10 1/10W 5% 0805 SMD Res, Wirewound,8.2 Ohm,2.5W,Flame Retardant BEE16_H_LOPROFILE_10P IC,TNY264P,L POWER SWITCHER 6W,DIP-8B IC,PC817A,PHOTOCOUPLER TRAN OUT CTR 80-160% 4-DIP Diode, Zener, 4.7V, 1/2W, 2%, DO-35
Page 7 of 22
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-35
Cell Phone Adapter TNY264
April 5, 2004
6 Transformer Specification
6.1 Electrical Diagram
NC W3 7 Turn #29AWG X3 1 1 W2 108Turn #33AWG 2
8
W4 8 Turn #28TIW X2
6 W1 18 Turns #33AWG X2 3 1
Figure 5 Transformer Electrical Diagram
6.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-5 to Pins 6-10 Pins 1-2, all other windings open, measured at 132 kHz, Pins 1-2, all other windings open Pins 1-2, with Pins 6-8 shorted, measured at 132 kHz. 3000 VAC 2030 H, -/+10% 620 kHz (Min.) 65 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
6.3
Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] Description 2 Core: PC40EE16, TDK or equivalent Gapped for AL of 173nH/T Bobbin: Horizontal 10 pin Magnet Wire: #33 AWG Magnet Wire: #29 AWG Bus wire #29AWG Triple Insulated Wire: #28 AWG. Tape: 3M 1298 Polyester Film, 2.0 mils thick, 8.4 mm wide Varnish
Page 8 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
6.4
Transformer Build Diagram
BOBBIN PRIMARY SIDE BOBBIN SECONDARY SIDE
6 Secondary 8 W4
W3 Shield 1 1 W2 Primary 2 1 3 W1 Core Shield
Figure 6 - Transformer Build Diagram.
6.5
Transformer Construction
Bobbin Preparation Core Cancellation Basic Insulation Primary Basic Insulation Shield Shield Basic Insulation Secondary Winding Outer Wrap Core Preparation Final Assembly
Place the bobbin item [2] in the winding machine with primary side oriented to the left hand side. Start at Pin 8 temporarily. Wind 18 bifilar turns of item [3] from right to left. Wind uniformly with tight tension across winding area. Finish on pin 3 Fold and attach the starting lead to pin 1 Use two layers of item [7] for basic insulation. Start at pin 2 wind 36 turns of item [3] from left to right, apply one layer of item [7]. Continue winding on a second layer. Wind 36 turns from right to left, apply one layer of item [7]. On a third layer wind 36 turns from left to right. Wind with tight tension across entire bobbin. Finish at pin 1 Use two layers of item [7] for basic insulation. Start at Pin 8 temporarily, wind 7 trifilar turns of item [4]. Wind from right to left with tight tension in a single layer across entire width of bobbin. Finish on Pin 1. Cut the starting lead right where the winding begins Use two layer of item [7] for basic insulation. Start at Pins 8. Wind 8 bifilar turns of item [6] Spread turns evenly across bobbin. Finish on Pin 6. Use two layer of item [7] for basic insulation. Assembly cores halves. Wind two turns of item [5] around the core. The wire should be placed very close to the primary pin side of the bobbin. Terminate the wire at pin 1. Varnish impregnate (item [8]). Cut pins 4,5,7,9,and 10 of Bobbin [2]
Page 9 of 22
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-35
Cell Phone Adapter TNY264
April 5, 2004
7 Transformer Spreadsheets
ACDC_TNY-II_Rev1_1_032701 INPUT Copyright Power Integrations Inc. 2001 ENTER APPLICATION VARIABLES VACMIN 90 VACMAX 265 fL 47 VO 5.4 PO 4.468979 62 n 0.67 Z 0.5 tC 3 CIN ENTER TinySwitch-II VARIABLES TNY-II Chosen Device ILIMITMIN ILIMITMAX fS fSmin fSmax VOR VDS VD KP 9.4 INFO OUTPUT UNIT ACDC_TNYII_Rev1_1_032701.xls: TinySwitch-II Continuous/Discontinuous Flyback Transformer Design Spreadsheet TRANSFORMER 1 Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power
Volts Volts Hertz Volts Watts
Efficiency Estimate Loss Allocation Factor mSecon Bridge Rectifier Conduction Time Estimate ds uFarads Input Filter Capacitor
TNY264 TNY264 Power Out 0.233 0.267 132000 120000 144000 80 10 0.5 0.60
Universa 115 Doubled/230V l 6W 9W Amps Amps Hertz Hertz Hertz Volts Volts Volts 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 (0.6ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE16 Core EE16 P/N: Bobbin EE16_BOBBIN P/N: AE 0.192 cm^2 LE 3.5 cm AL 1140 nH/T^2 BW 8.6 mm M 0 mm L NS DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG IP IR IRMS TRANSFORMER PRIMARY DESIGN PARAMETERS LP NP ALG BM BAC ur LG 3 8
PC40EE16-Z BE-16-118CPH 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) Number of Primary Layers Number of Secondary Turns
73 Volts 375 Volts
Minimum DC Input Voltage Maximum DC Input Voltage
0.56 0.09 0.23 0.14 0.13
Amps Amps Amps Amps
Maximum Duty Cycle Average Primary Current Minimum Peak Primary Current Primary Ripple Current Primary RMS Current
2035 108 173 2609 683 1654 0.12
uHenries Primary Inductance Primary Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Gauss Flux Density, IP (BP<3000) Gauss AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core mm Gap Length (Lg > 0.1 mm) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
Page 10 of 22
DER-35
BWE OD INS DIA AWG CM CMA
Cell Phone Adapter TNY264
25.8 0.24 0.05 0.19 33 mm mm mm mm AWG
April 5, 2004
Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) 51 Cmils Bare conductor effective area in circular mils 405 Cmils/A Primary Winding Current Capacity (200 < CMA < 500) mp
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT / SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 3.16 Amps Peak Secondary Current ISRMS 1.51 Amps Secondary RMS Current IO 0.83 Amps Power Supply Output Current IRIPPLE 1.27 Amps Output Capacitor RMS Ripple Current CMS 303 Cmils Secondary Bare Conductor minimum circular mils AWGS 25 AWG Secondary Wire Gauge (Rounded up to next larger standard AWG value) DIAS 0.46 mm Secondary Minimum Bare Conductor Diameter ODS 1.08 mm Secondary Maximum Outside Diameter for Triple Insulated Wire INSS 0.31 mm Maximum Secondary Insulation Wall Thickness VOLTAGE STRESS PARAMETERS VDRAIN PIVS
563 Volts 33 Volts
Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage
Page 11 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
8 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 8.1 Efficiency
EFFICIENCY VS LINE VOLTAGE
70 60 Output Efficiency (%) 50 40 30 20 10 0 80 100 120 140 160 180 200 220 240 260 280 Input Voltage (AC) Iout=650mA
Figure 7- Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
EFFICIENCY VS OUTPUT CURRENT
70 60 Output Efficiency (%) 50 40 30 20 10 0 0 100 200 300 400 500 600 700 Output Current (mA) Vin=115 Vin230
Figure 8. Efficiency VS Output Load. Room Temperature, 60 Hz.
Page 12 of 22
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DER-35 8.2 No-load Input Power
Cell Phone Adapter TNY264
April 5, 2004
NO LOAD INPUT POWER
0.40 0.35 0.30 Input power (W) 0.25 0.20 0.15 0.10 0.05 0.00 80 100 120 140 160 180 200 220 240 260 280 Input Voltage (AC)
Figure 9- Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
8.3
Output Characteristic.
OUTPUT CHARACTERISTIC
5.7 5.1
6 5 4 3
Output Voltage (DC)
o
2 1 0 0 100
Vin=115V Vin=230
200
300
400
500
600
700
800
Output Current (mA)
Figure 10 -Output Characteristic, 25 oC
Page 13 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
OUTPUT CHARACTERISTIC AT VIN=230V
5.7 5.1
6 5 4 3
Output Voltage (DC)
o 2 1 0 0 100 200 300 400 500 600 700 800 Output Current (mA)
Esternal Temp=40C External Temp= 25C External Temp=0C
Figure 11. Output Characteristic at different ambient temperatures
8.4
Line Regulation LINE REGULATION
8 7 Output Voltage (DC) 6 5 4 3 2 1 0 80 100 120 140 160 180 200 220 240 260 280 Line Voltage (AC)
Iout=650mA
Figure 12 - Line Regulation, Room Temperature, Full Load.
Page 14 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
9 Thermal Performance
Measurements were done with the supply enclosed in its case.
Temperature (C) Item Ambient (C) Transformer (T1) Blocking Diode (D5) TinySwitch-II (U1) Output Rectifier (D7) Vin=90VAC Vin=115VAC Vin=230VAC
25 73 71 97 69
25 70 67 77 68
25 69 65 69 67
Page 15 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
10 Waveforms
10.1 Drain Voltage and Current, Normal Operation
Figure 13 - 90 VAC, Full Load. Upper: IDRAIN, 0.1 A / div Lower: VDRAIN, 100 V, 5 s / div
Figure 14 - 264 VAC, Full Load Upper: IDRAIN, 0.1 A / div Lower: VDRAIN, 200 V / div
10.2 Output Voltage Start-up Profile
Figure 15 - Start-up Profile, 115VAC 1 V, 2 ms / div.
Figure 16 - Start-up Profile, 230 VAC 1 V, 2 ms / div.
Page 16 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
10.3 Drain Voltage and Current Start-up Profile
Figure 17 - 90 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V & 5us / div.
Figure 18 - 264 VAC Input and Maximum Load. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 200 V & 2us / div.
10.4 Load Transient Response (75% to 100% Load Step) In the figures shown below, the oscilloscope was triggered using the load current step as a trigger source.
Figure 19 - Transient Response, 115 VAC, 75-10075% Load Step. Top: Load Current, 0.2 A/div. Bottom: Output Voltage 200 mV, 1ms / div.
Figure 20 - Transient Response, 230 VAC, 75-10075% Load Step Upper: Load Current, 0.2 A/ div. Bottom: Output Voltage 200mV, 1ms / div.
Page 17 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
10.5 Out put Ripple Measurements 10.5.1 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 21 and Figure 22. 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) 10.0 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 21 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 22 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
Page 18 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
10.5.2 Measurement Results
Figure 23 - Output Ripple, 85 VAC, Full Load. 10us, 50 mV / div
Figure 24 - Output Ripple, 115 VAC, Full Load. 10us, 50 mV / div
Figure 25 - Output Ripple, 230 VAC, Full Load. 10us, 50 mV /div
Page 19 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
11 Conducted EMI
Figure 26 - Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits.
Figure 27 - Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits.
Page 20 of 22
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DER-35
Cell Phone Adapter TNY264
April 5, 2004
12 Revision History
Date April 5, 2004 Author VC Revision 1.0 Description & changes Initial release Reviewed AM / VC
Page 21 of 22
Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-35
Cell Phone Adapter TNY264
April 5, 2004
For the latest updates, visit our Web site: 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 LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION 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. (c) Copyright 2004, Power Integrations.
WORLD HEADQUARTERS Power Integrations 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 e-mail: usasales@powerint.com AMERICAS Power Integrations, Inc. 4335 South Lee Street, Suite G, Buford, GA 30518, USA Phone: +1-678-714-6033 Fax: +1-678-714-6012 e-mail: usasales@powerint.com
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SINGAPORE (ASIA PACIFIC HEADQUARTERS) Power Integrations, Singapore 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com TAIWAN Power Integrations International Holdings, Inc. 17F-3, No. 510, Chung Hsiao E. Rd., Sec. 5, Taipei, Taiwan 110, R.O.C. Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com UK (EUROPE & AFRICA HEADQUARTERS) 1st Floor, St. James's House East Street Farnham, Surrey GU9 7TJ United Kingdom Phone: +44-1252-730-140 Fax: +44-1252-727-689 e-mail: eurosales@powerint.com
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APPLICATIONS FAX World Wide +1-408-414-9760
ER or EPR template - Rev 3.4 - Single sided Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
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