Reference Design Report for a 7.5 W
Title
Continuous, 13 W Peak DVD / Set Top Box
Using TNY376PN
85–265 VAC Input, 3.3 V (500 mA), 5 V (500 mA),
Specification
12 V (250 mA) and –12 V (30 mA) Outputs
Application DVD / Set Top Box
Author Power Integrations Applications Department
Document
RDR-115
Number
Date May 22, 2007
Revision 1.0
Summary and Features
• Excellent cross regulation without need for post regulator
• EcoSmart
• No-load consumption <150 mW at 265 VAC (no bias winding required)
• > 70% active-mode efficiency
• > 0.5 W output power available for 1 W input simplifies DVD player design
• BP/M capacitor value selects MOSFET current limit for greater design flexibility
• Tightly toleranced I
• Increases MOSFET and magnetics power delivery
• Reduces overload power, which lowers output diode and capacitor costs
• Integrated TinySwitch-PK Safety/Reliability features:
• Accurate (± 5%), auto-recovering, hysteretic thermal shutdown function maintains
safe PCB temperatures under all conditions
• Auto-restart protects against output short circuit and open loop fault
conditions
• > 3.2 mm creepage on package enables reliable operation in high humidity
and high pollution environments
• Meets EN550022 and CISPR-22 Class B conducted EMI with >20 dBµV margin
®
– Meets Energy Star / CEC requirements
2
f parameter (–10%, +12%) reduces system cost:
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The products and applications illustrated herein (includin g 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 foreig n
patent applications assigned to Power Integrations. A complete list of Power Integrations’ pate nts may be found at
www.powerint.com
.
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Table of Contents
1 Introduction .................................................................................................................5
2 Power Supply Specification ........................................................................................6
3 Schematic ...................................................................................................................7
4 Circuit Description.......................................................................................................8
4.1 Input EMI Filtering................................................................................................8
4.2 TinySwitch-PK Primary ........................................................................................8
4.3 Output Feedback .................................................................................................9
4.4 Bypass/Multifunction Pin......................................................................................9
5 PCB Layout...............................................................................................................10
6 Bill of Materials .........................................................................................................11
7 Transformer Specification .........................................................................................13
7.1 Electrical Diagram..............................................................................................13
7.2 Electrical Specifications .....................................................................................13
7.3 Materials ............................................................................................................13
7.4 Transformer Build Diagram................................................................................14
7.5 Copper Foil Preparation.....................................................................................14
7.6 Transformer Construction ..................................................................................15
8 Design Spreadsheet .................................................................................................16
9 Performance Data.....................................................................................................18
9.1 Efficiency ...........................................................................................................18
9.1.1 Active Mode CEC Measurement Data ........................................................18
9.2 No-load Input Power ..........................................................................................19
9.3 Available Standby Output Power .......................................................................20
9.4 Regulation .........................................................................................................21
9.4.1 Load Regulation, Room Temperature, 115 VAC input. ..............................21
9.4.2 Line.............................................................................................................23
10 Thermal Performance............................................................................................24
11 Waveforms ............................................................................................................25
11.1 Drain Voltage and Current, Normal Operation ................................................... 25
11.2 Output Voltage Start-up Profile ..........................................................................25
11.3 Drain Voltage and Current Start-up Profile ........................................................26
11.4 Load Transient Response..................................................................................26
11.5 Output Ripple Measurements ............................................................................ 29
11.5.1 Ripple Measurement Technique .................................................................29
11.5.2 Measurement Results.................................................................................30
11.6 Line Surge .........................................................................................................31
12 Conducted EMI .....................................................................................................32
13 Appendix A ............................................................................................................33
13.1 Output Power Delivery Using a TNY375P .........................................................33
14 Revision History ....................................................................................................34
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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.
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1 Introduction
This document is an engineering report describing a four output flyback power supply
utilizing a TNY376PN. This power supply is intended as a general purpose evaluation
platform for TinySwitch-PK
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.
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2 Power Supply Specification
Description Symbol Min Typ Max Units Comment
Input
Voltage
Frequency
No-load Input Power (230 VAC) 0.3 W
Output
Output Voltage 1
Output Ripple Voltage 1
Output Current 1
Output Voltage 2
Output Ripple Voltage 2
Output Current 2
Output Voltage 3
Output Ripple Voltage 3
Output Current 3
Output Voltage 4
Output Ripple Voltage 4
Output Current 4
Total Output Power
Continuous Output Power
V
f
IN
LINE
85 265 VAC
47 50/60 64 Hz
2 Wire – no P.E.
V
OUT1
V
RIPPLE1
I
OUT1
V
OUT2
V
RIPPLE2
I
OUT2
V
OUT3
V
RIPPLE3
I
OUT3
V
OUT4
V
RIPPLE4
I
OUT4
3.135 3.3 3.465 V
100 mV
0.1 0.5 0.6 A
4.75 5.0 5.35 V
66 mV
0.2 0.5 0.6 A
10.8 12.0 13.8 V
240 mV
0.1 0.25 0.64 A
-10.8 -12.0 -13.8 V
240 mV
0.03 0.03 0.03 A
± 5%
20 MHz bandwidth
+7%,-5%
20 MHz bandwidth
+15%, -10%
20 MHz bandwidth
+15%, -10%
20 MHz bandwidth
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3 Schematic
Page 7 of 36
Figure 2 – Schematic.
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4 Circuit Description
4.1 Input EMI Filtering
One requirement of this design was to meet conducted EMI with the output return
connected to safety earth ground. This simulates the condition where the DVD player or
set-top box is earth grounded either by an antenna or cable TV input cable.
The EMI filtering consists of a π filter formed by C1, L1 and C4 together with capacitor
C8. A common mode choke was selected over discrete inductors for L1 to meet the earth
grounded requirement. Such a simple arrangement was possible due to the switching
frequency jitter feature of U4 and the E-Shield™ techniques used in the transformer.
Provision for an additional X class capacitor (C3) is made on the board but is not
required.
4.2 TinySwitch-PK Primary
The TNY376 (U4) has the following functions integrated onto a monolithic IC: a 700 V
power MOSFET, a low-voltage CMOS controller, a high-voltage current source (provides
startup and steady-state operational current to the IC), hysteretic thermal shutdown, and
auto-restart. The excellent switching characteristics of the integrated power MOSFET
allow efficient operation up to 132 kHz (264 kHz in Peak Power Mode).
Under normal operation, the rectified and filtered input voltage is applied to one side of
the primary winding of T1. The other side of the T1 primary winding is connected to the
DRAIN pin of U4. As soon as the voltage is applied across the DRAIN and SOURCE
pins of U4, the internal high voltage current source (connected to the DRAIN pin of the
IC) begins charging the capacitor (C19) connected to the BYPASS/MULTIFUNCTION
(BP/M) pin. Once the voltage across C19 reaches 5.8 V, the controller enables MOSFET
switching. MOSFET current is sensed (internally) by the voltage developed across the
Drain to Source resistance (R
preset (internal) current-limit trip point (I
The controller regulates the output voltage by skipping switching cycles (ON/OFF control)
whenever the output voltage is above the reference level. During normal operation,
MOSFET switching is disabled whenever the current flowing out of the EN/UV pin is
greater than 90 µA. If less than 90 µA is flowing out of the EN/UV pin when the
oscillator’s (internal) clock signal occurs, MOSFET switching is enabled for that switching
cycle, and the MOSFET turns on. That switching cycle terminates when the current
through the MOSFET reaches I
switching cycles will be skipped (disabled) resulting in a high effective switching
frequency. As the load reduces, more switching cycles are skipped, which reduces the
effective switching frequency. At no-load, most switching cycles are skipped, which is
what makes the no-load power consumption of supplies designed around the
TinySwitch-PK family so low, since switching losses are the dominant loss mechanism at
light loading. Additionally, since the amount of energy per switching cycle is fixed by
) while it is turned on. When the current reaches the
DS(ON)
), the controller turns the MOSFET off.
LIMIT
, or the DC
LIMIT
signal is encountered. At full load, few
MAX
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22-May-07 RDR-115 7.5 W, 13 W pk Multi-Output DVD/Set-Top Box Supply
I
, the skipping of switching cycles gives the supply a fairly consistent efficiency over
LIMIT
the load range.
The TinySwitch-PK can supply additional output power to the load for short periods of
time. If the MOSFET switching occurs for 14 consecutive clock cycles (132 kHz), the I
LIMIT
increases, and the MOSFET is enabled to switch at 264 kHz. While in the Peak Power
Mode of operation, if the MOSFET is disabled (via the feedback loop) for 12 consecutive
clock cycles (264 kHz), then the TinySwitch-PK reverts back to its normal mode of
operation at 132 kHz.
To limit the peak drain voltage spike caused by leakage inductance D5, R5, VR1, R7 and
C2 form a clamp network. This arrangement offers the low EMI performance of an RCD
clamp with the energy efficiency of a Zener clamp. By limiting the voltage across R7 and
C2 using a Zener, the clamp voltage does not collapse as the output load, and therefore
effective switching frequency, reduces. This prevents the clamp becoming a significant
load at light load and therefore maintains high efficiency and low no-load input power.
4.3 Output Feedback
The output voltages of the +3.3 V and +5 V outputs are regulated by the sum of the
currents through R15 and R16. The combined currents passing through R13 are
regulated at 2.5 Volts by U3. If the voltage changes across R13, U3 changes the current
through U2A (opto’s LED), which proportionately changes the current through U2B
(opto’s transistor). If the collector current of U2B is greater than 90 µA, U4 will skip the
next switching cycle. If not, the switching cycle will occur. Sensing the outputs voltages
via R15 and R16 helps improve the cross regulation between these outputs. The ±12 V
outputs are cross regulated via the transformer’s turns ratios. Optional capacitor C7
provides soft-finish, reducing the output voltage slew rate at start-up.
4.4 Bypass/Multifunction Pin
The TinySwitch-PK’s BP/M pin can be used to set the peak current limit of the primary
switching cycle. This allows the designer more flexibility to optimize the power supply for
the specific power range. Setting the current limit is done by selecting a capacitor value
that is connected to the BP/M pin. The selection sizes are: 1.0 µF, 0.1 µF and 10 µF.
This sets the peak current threshold to the minimum, typical, and maximum level. Refer
to the data sheet for the specific current limit for each TinySwitch-PK device.
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Page 10 of 36
22-May-07 RDR-115 7.5 W, 13 W pk Multi-Output DVD/Set-Top Box Supply
6 Bill of Materials
Item Qty
1 2 C1 C4 22 µF
2 1 C2 10 nF 10 nF, 1 kV, Disc Ceramic 562R5HKMS10 Vishay/Sprague
3 1 C3 47 nF 47 nF, 275 VAC, Film, X2 ECQU2A473ML Panasonic
4 2 C6 C15 220 µF
5 2 C7 C19 10 µF
6 1 C8 330 pF 330 pF, Ceramic Y1 440LT33-R Vishay
7 1 C9 47 µF
8 2 C11 C12 1000 µF
9 1 C14 100 nF
Part
Reference
Value Description Mfg Part Number Mfg
22 µF, 400 V, Electrolytic, Low
ESR, 901 mΩ, (16 x 20)
220 µF, 25 V, Electrolytic, Very
Low ESR, 72 mΩ, (8 x 11.5)
10 µF, 50 V, Electrolytic, Gen.
Purpose, (5 x 11)
47 µF, 25 V, Electrolytic, Very
Low ESR, 300 mΩ, (5 x 11)
1000 µF, 10 V, Electrolytic,
Very Low ESR, 41 mΩ, (8 x 20)
100 nF, 50 V, Ceramic, Z5U,
.2 Lead Space
EKMX401ELL220ML20S
EKZE250ELL221MHB5D
EKMG500ELL100ME11D
EKZE250ELL470ME11D
EKZE100ELL102MH20D
C317C104M5U5TA Kemet
Nippon
Chemi-Con
Nippon
Chemi-Con
Nippon
Chemi-Con
Nippon
Chemi-Con
Nippon
Chemi-Con
10 2 C17 C18 470 µF
11 1 C20 100 µF
12 3 D1 D2 D5 FR106
13 2 D3 D4 1N4007 1000 V, 1 A, Rectifier, DO-41 1N4007 Vishay
14 2 D7 D8 UF4003
15 1 D10 SB340 40 V, 3 A, Schottky, DO-201AD SB340-E3 Vishay
16 1 D11 1N5819 40 V, 1 A, Schottky, DO-41 1N5819-E3 Vishay
17 1 F1 3.15 A 3.15 A, 250 V, Fast, TR5 37013150410 Wickman
18 1 J1 CON2
Page 11 of 36
470 µF, 10 V, Electrolytic, Very
Low ESR, 72 mΩ, (8 x 11.5)
100 µF, 25 V, Electrolytic, Very
Low ESR, 130 mΩ, (6.3 x 11)
800 V, 1 A, Fast Recovery
Diode, 500 ns, DO-41
200 V, 1 A, Ultrafast Recovery,
50 ns, DO-41
2 Position (1 x 2) header, 0.312
pitch, Vertical
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EKZE100ELL471MHB5D
EKZE250ELL101MF11D
FR106 Diodes Inc.
UF4003-E3 Vishay
26-50-3039 Molex
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Chemi-Con
Nippon
Chemi-Con
RDR-115 7.5 W, 13 W pk Multi-Output DVD/Set-Top Box Supply 22-May-07
19 1 J2 CON8
20 1 JP1 J
21 1 JP2 J
22 1 L1 5 mH
23 3 L2 L3 L4 3.3 uH 3.3 uH, 5.5 A RL622-3R3K-RC JW Miller
24 1 R5 47 47 R, 5%, 1/4 W, Carbon Film CFR-25JB-47R Yageo
25 1 R7 100 100 R, 5%, 1/4 W, Carbon Film CFR-25JB-100R Yageo
26 1 R8 1 k 1 k, 5%, 1/4 W, Carbon Film CFR-25JB-1K0 Yageo
27 1 R9 200 200 R, 5%, 1/4 W, Carbon Film CFR-25JB-200R Yageo
28 1 R10 3.3 k 3.3 k, 5%, 1/4 W, Carbon Film CFR-25JB-3K3 Yageo
29 1 R12 1 1 R, 5%, 1/2 W, Carbon Film CFR-50JB-1R0 Yageo
8 Position (1 x 8) header, 0.156
pitch, Vertical
Wire Jumper, insulated,
22 AWG, 0.3 in,
Wire Jumper, insulated,
22 AWG, 1.3 in
5 mH, 0.3 A, Common Mode
Choke
26-48-1081 Molex
298 Alpha
298 Alpha
HT9V-03050 CUI
30 1 R13 10 k 10 k, 1%, 1/4 W, Metal Film ERO-S2PHF1002 Panasonic
31 1 R15 20 k 20 k, 1%, 1/4 W, Metal Film MFR-25FBF-20K0 Yageo
32 1 R16 6.34 k 6.34 k, 1%, 1/4 W, Metal Film MFR-25FBF-6K34 Yageo
Bobbin
33 1 T1 EEL19
34 1 U2 LTV817A
35 1 U3 TL431
36 1 U4 TNY376P
37 1 VR1
*A TNY375P can be used for U4, with a reduced power output. See Appendix A in this report.
P6KE180A 180 V, 5 W, 5%, TVS,
Bobbin, EEL19, Horizontal, 12
pins (5 x 7)
Optocoupler, 35 V, CTR 80-
160%, 4-DIP
2.495 V Shunt Regulator IC,
2%, 0 ºC to 70 ºC, TO-92
TinySwitch-PK, TNY376P,
DIP-8C
DO204AC (DO-15)
CWS-T1-DAK-115
SIL6041
TELP-32280-0001
R1396
LTV-817A Liteon
TL431CLPG
TNY376P
P6KE180ARLG On Semi
Ngai Cheong
Elect Ltd
CWS
Hical
Precision
Santronics
On
Semiconductor
Power
Integrations
Note: Parts listed above are RoHS compliant.
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7 Transformer Specification
7.1 Electrical Diagram
1
6
W2
Primary
W3
6T x 4 # 29AW G
Bias
W1
Shield 1
Figure 4 – Transformer Electrical Diagram.
7.2 Electrical Specifications
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage Inductance
W6
+12 V
W5
+5 V
7
W4
+3.3 V
W7
-12 V
74T # 29AWG
4
3
5
NC
34T #28AWG
1
4T x 2 #26AW G
11
Foil
1T
2T
Foil
8,9,10
7T x 2 #26AW G
12
60Hz 1 second, from Pins 1-5 to Pins 6-12 3000 V ac
Pin 1 to Pin 4, all other windings open
Measured at 132 kHz.
Pin 1 to Pin 4, all other windings open 300 kHz (Min.)
Pin 1 to Pin 4, Pins 6-12 shorted
0.813 mH +/- 12%
30 µH Max.
7.3 Materials
Item Description
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
Page 13 of 36
Core: EEL19, Nicera NC-2H or equiv. gapped for AL of 150 nH/T
Bobbin: EEL19 Horizontal 12 pins
Magnet Wire: # 28 AWG
Magnet Wire: # 29 AWG
Magnet Wire: # 26 AWG
Teflon Tubing # 22
Margin Tape: 3M # 44 Polyester web. 3.0 mm wide
Copper Foil 0.52 mm thick, 12 mm wide.
Tape for Copper 2.0 mils thick, 16 mm wide.
Tape: 3M 1298 Polyester Film, 12.8 mm wide
Tape: 3M 1298 Polyester Film, 18.2 mm wide
Varnish
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7.4 Transformer Build Diagram
Pin Side
8,9,10
8, 9,10
12
11
7
6
11
3
-12 V
+12 V
5
4
1
+3.3 and +5 V
Bias
Primary
1
NC = No Connection to a pin
Figure 5 – Transformer Build Diagram.
Shield 1
NC
7.5 Copper Foil Preparation
The following figure shows the copper foils to be used for +3.3 V and +5 V outputs (W4
and W5)
Finish Pin 11
#26 Copper
Wire
50mm
Connect Pin 7
+5 Vout 1T Copper Foil 12.0 mm
0.52mm Thick.
#26 Copper
Start Pin 8,9,10
Wire
77mm
+3.3 Vout 2T Copper Foil 12.0mm
0.52mm Thick.
Figure 6 – Copper Foil Diagram.
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7.6 Transformer Construction
Bobbin Set Up
Orientation
Margin Tape
W1 Shield 1
Basic Insulation
Set up the bobbin with pin #1 oriented to the left-hand side.
Apply 3.0 mm margin at each side of bobbin using item [7]. Match combined height
of primary, shield and bias windings.
Start with a floating lead temporary tie on pin 8. Wind 34 turns of item [3] from right
to left. Wind tightly and uniformly across entire width of bobbin. Finish at pin 1
using item [6] at the finish leads. Remove the wire from pin 8 and cut the starting
lead just at the starting of the winding.
Apply one layer of tape item [10].
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8 Design Spreadsheet
ACDC_TinySwitch-PK_
041207; Rev.0.22; Copyright
Power Integrations 2007
ENTER APPLICATION VARIABLES
VACMIN 85 Volts Minimum AC Input Voltage
VACMAX 265 Volts Maximum AC Input Voltage
fL 50 Hertz AC Mains Frequency
VO 5.00 Volts Output Voltage (at continuous power)
Peak Load Current, IO 2.60 Amps Power Supply Output Current (corresponding to peak power)
Peak Power 13.00 Watts Peak Output Power. Used in estimation of Primary
Continuous / Average Power 7.5 7.5 Watts Continuous/Average Output Power. Used in estimation of
n 0.67 Efficiency Estimate at output terminals. Under 0.7 if no better
Z 0.6 Z Factor. Ratio o f secondary side losses to the total losses in
tC 3.00 mSecon
CIN 44.00 44 uFarads Input Capacitance
ENTER TinySwitch-PK VARIABLES
TinySwitch-PK TNY376 TNY376 User defined TinySwitch-PK
Chosen Device TNY376
Chose Configuration INC Increase
ILIMITMIN 0.465 Amps Minimum Current Limit
ILIMITTYP 0.500 Amps
ILIMITMAX 0.535 Amps Maximum Current Limit
fSmin 248000 Hertz Minimum Device Switching Frequency
I^2fmin 59.40 A^2kHz I^2f (product of c urrent limit squared and frequency is
PO_132kHz 8.77 Watts Estimated Maximum Power while still in 132 kHz operation
VOR 135.00 135 Volts Reflected Output Voltage (VOR < 135 V Recommended)
VDS 10 Volts TinySwitch-PK on-state Drain to Source Voltage
VD 0.5 Volts Output Winding Diode Forward Voltage Drop
KP 0.53 Ripple to Peak Current Ratio (KP < 6)
KP_TRANSIENT 0.36 Transient Ripple to Peak Current Ratio. Ensure
ENTER BIAS WINDING VARIABLES
VB 22.00 Volts Bias Winding Voltage
VDB 0.70 Volts
NB 12.00 Bias Winding Number of Turns
VZOV 28.00 Volts Over Voltage P rotection zener diode.
UVLO VARIABLES
V_UV_TARGET 100.07 Volts Target under-voltage threshold, above which the power
V_UV_ACTUAL 914.70 Volts Typical start-up voltage based on standard value of
RUV_IDEAL 3.91 Mohms Calculated value for UV Lockout resistor
RUV_ACTUAL 36.50 Mohms Closest standard value of resistor to RUV_IDEAL
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type EEL19 EEL19 User defined Core Size (Verify thermal performance under
INPUT INFO
OUTPU
T
d
Current
Limit
ACDC_TinySwitch-PK_041207_Rev0-22.xls;
UNIT
TinySwitch-PK Continuous/Discontinuous
Flyback Transformer Design Spreadsheet
inductance
Core size
data available
the power supply. Use 0.6 if no better data available
Bridge Rectifier Conduction Time Estimate
ds
Enter "RE D" for reduced current limit (sealed adapters),
"STD" for standard current limit or "INC" for increased current
limit (peak or higher power applications)
trimmed for tighter tolerance)
KP_TRANSIENT > 0.25
supply will start
RUV_ACTUAL
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continuous load conditions)
Core EEL19 P/N: PC40EE19/27/5-Z
Bobbin EEL19_
BOBBIN
AE 0.2454 cm^2 Core Effective Cross Sectional Area
LE 6.185 cm Core Effective Path Length
AL 720 nH/T^2 Ungapped Core Effective Inductance
BW 19.7 mm Bobbin Physical Winding Width
M 3.00 3 mm Safet y Margin Width (Half the Primary to Secondary
L 2.00 2 Number of Primary Layers
NS 3 Number of Secondary Tu rns
DC INPUT VOLTAGE PARAMETERS
VMIN 91 Volts Minimum DC Input Voltage
VMAX 375 Volts Maximum DC Input Voltage
CURRENT WAVEFORM SHAPE PARAMETERS
DMAX 0.63 Duty Ratio at full load, minimum primary inductance and
IAVG 0.24 Amps Average Primary Current
IP 0.47 Amps Minimum Peak Primary Current
IR 0.25 Amps Primary Ripple Current
IRMS 0.32 Amps Primary RMS Current
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP 813 uHenries Typical Primary Inductance. +/- 12% to ensure a minimum
LP_TOLERANCE 12 % Primary inductance tolerance
NP 74 Primary Winding Number of Turns
ALG 150 nH/T^2 Gapped Core Effective Inductance
BM 2406 Gauss Maximum Operating Flux Density at LP_TYP and
BAC 641 Gauss AC Flux Densit y for Core Loss Curves (0.5 X Peak to Peak)
ur 1444 Relative Permeability of Ungapped Core
LG 0.16 mm Gap Length (Lg > 0.1 mm)
BWE 27.4 mm Effective Bobbin Width
OD 0.37 mm Maximum Primary Wire Diameter including insulation
INS 0.06 mm Estimated Total Insulation Thickness (= 2 * film thickness)
DIA 0.31 mm Bare conductor d iameter
AWG 29 AWG Primary Wire Gauge (Rounded to next smaller sta ndard
CM 128 Cmils Bare conductor effective area in circular mils
CMA 404 Cmils/A
TRANSFORMER SECONDARY DESIGN PARAMETERS
Lumped parameters
ISP 11.41 Amps Peak Secondary Current
ISRMS 6.03 Amps Secondary RMS Current
IRIPPLE 5.44 Amps Output Capacitor RMS Ripple Current
CMS 1206 Cmils Secondary Bare Conductor minimum circular mils
AWGS 19 AWG Secondary Wire Gauge (Rounded up to next larger standard
VOLTAGE STRESS PARAMETERS
VDRAIN 678 Volts Maximum Drain Voltage Estimate (Assumes 20% zener
PIVS 20 Volts Output Rectifier Maximum Peak Inverse Voltage
P/N: EEL19_BOBBIN
Creepage Distance)
minimum input voltage
primary inductance of 725 uH
ILIMITMAX, BM<3200 is recommended
AWG value)
Primary Winding Current Capacity (200 < CMA < 500)
mp
AWG value)
clamp tolerance and an additional 10% temperature
tolerance)
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9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency.
9.1 Efficiency
100
90
80
70
60
50
40
Efficiency
30
20
10
0
0123456789
Outp u t Po we r (Watts )
85 VAC
115 VAC
230 VAC
265 VAC
Figure 7 – Efficiency vs. Output Power, Room Temperature, 60 Hz.
9.1.1 Active Mode CEC Measurement Data
All single output adapters, including those provided with products, for sale in California
after Jan 1st, 2007 must meet the California Energy Commission (CEC) requirement for
minimum active mode efficiency and no load input power. Minimum active mode
efficiency is defined as the average efficiency of 25, 50, 75 and 100% of rated output
power with the limit based on the nameplate output power:
Nameplate Output (PO) Minimum Efficiency in Active Mode of Operation
< 1 W
≥ 1 W to ≤ 49 W 0.09 × ln (P
0.49 × P
) + 0.5 [ln = natural log]
O
O
> 49 W 0.84 W
For adapters that are single input voltage only, the measurement is made at the rated
single nominal input voltage (115 VAC or 230 VAC); for universal input adapters the
measurement is made at both nominal input voltages (115 VAC and 230 VAC).
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To meet the standard, the measured average efficiency (or efficiencies for universal input
supplies) must be greater than or equal to the efficiency specified by the CEC/Energy
Star standard.
Percent of
Full Load
Efficiency (%)
115 VAC 230 VAC
25 83.9 78.2
50 78.2 73.5
75 75.0 74.2
100 73.8 73.1
Average 77.7 74.8
CEC
specified
minimum
68.1
average
efficiency (%)
More states within the USA and other countries are adopting this standard; for the latest
up to date information please visit the PI Green Room:
http://www.powerint.com/greenroom/regulations.htm
9.2 No-load Input Power
0.14
0.12
0.1
0.08
0.06
Pin (Watts)
0.04
0.02
0
Figure 8 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
Page 19 of 36
0 50 100 150 200 250 300
Vin (VAC)
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9.3 Available Standby Output Power
The chart below shows the available output power vs line voltage for an input power of
1 W, 2 W and 3 W.
2.5
2
1.5
1
Output Power (Watts)
0.5
0
0 50 100 150 200 250 300
1 Watt I nput Power
2 Watts I nput Power
3 Watts I nput Power
Input Voltage (Volts)
Figure 9 – Output Power vs. Line Voltage.
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V
R
9.4 Regulation
9.4.1 Load Regulation, Room Temperature, 115 VAC input
These results represent the total variation as all outputs are swept from minimum to
maximum load.
4
3.8
3.6
3.465
3.4
3.2
3.135
VOLTS
3
2.8
2.6
2.4
2.2
2
02468
3.3 VOLT REGULATION Vs PS OUTPUT POWE
3.37
3.36
3.31
3.22
3.2
3.29
3.3
3.28 3.28 3.28
3.27
3.28
OUTPUT POWER (WATTS)
10 12 14
+3.3 V REGULATION
UPPER LIMIT
LOWER LIMIT
16
Figure 10 – 3.3 V Regulation vs. total output power.
6
5.8
5.6
5.4
5.35
5.2
5
OLTS
4.8
4.75
4.6
4.4
4.2
4
02468
Figure 11 – 5.0 V Regulation vs. total output power.
+5 VOLT REGULATION Vs PS OUTPUT POWER
5.26
5.3
5.1
5.07
5.07
4.99
4.83
5
5.04
4.79
5.06 5.06
OUTPUT POWER (WATTS)
10 12 14
+5 V REGULATION
UPPER LIMIT
LOWER LIMIT
16
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V
T
V
15
14.5
14
13.8
13.5
13
12.5
OLTS
12
11.5
11
10.8
10.5
10
0 2 4 6 8 10121416
12.28
12.47
12.92
13.03
Figure 12 – +12 V Regulation vs. total output power.
+12 VOLT REGULATION
13.08
13.11
13.03
12.99
12.52
11.74
OUTPUT POWER (WATTS)
12.26
11.9
+12 V REGULATION
UPPER LIMI
LOWER LIMIT
15
14.5
14
13.8
13.5
13
12.5
OLTS
12
11.5
11
10.8
10.5
10
0246810121416
12.41
Figure 13 – -12 V Regulation vs. total output power.
12.68
13.13
13.26
12.76
-12 VOLT REGULATION
13.38
13.44
13.34
13.28
12.2
OUTPUT POWER (WATTS)
12.78
-12 V CROSS REGULATION
UPPER LIMIT
LOWER LIMIT
12.8
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Page 23 of 36
RDR-115 7.5 W, 13 W pk Multi-Output DVD/Set-Top Box Supply 22-May-07
10 Thermal Performance
Output was loaded to 7.51 W. RD-115 was housed in the intended enclosure, which was
within a box inside the thermal test chamber (no air flow permitted). Ambient
temperature was measured inside the enclosure. Test chamber temperature was set to
50 °C.
Item
Ambient
TNY376 (U4)
Temperature (°C)
85 VAC 115 VAC 230 VAC
54.5 °C 54 °C 56.2 °C
92 °C 92.6 °C 94.5 °C
90 VAC, 7.5 W load, 21ºC Ambient
Figure 15 – Infrared Thermograph of Open Frame Operation, at Room Temperature
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11 Waveforms
11.1 Drain Voltage and Current, Normal Operation
Figure 16 –
85 VAC, Full Load.
Upper: I
Lower: V
, 0.2 A / div.
DRAIN
, 100 V, 2 µs / div.
DRAIN
11.2 Output Voltage Start-up Profile
Figure 18 – Start-up Profile, 115 VAC.
Bottom Trace: 5 V Output at 5 V / div.
Next Trace: 3.3 V Output at 5 V / div.
Next Trace: +12 V Output at 10 V / div.
Top Trace: -12 V Output at 10 V / div.
20 ms / div.
Figure 17 –
265 VAC, Full Load
Upper: I
Lower: V
, 0.2 A / div.
DRAIN
, 200 V / div.
DRAIN
Figure 19 – Start-up Profile, 230 VAC.
Bottom Trace: 5 V Output at 5 V / div.
Next Trace: 3.3 V Output at 5 V / div.
Next Trace: +12 V Output at 10 V / div.
Top Trace: -12 V Output at 10 V / div.
20 ms / div
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11.3 Drain Voltage and Current Start-up Profile
Figure 20 – 85 VAC Input and Maximum Load.
Upper: I
Lower: V
, 0.5 A / div.
DRAIN
, 100 V & 1 ms / div.
DRAIN
Figure 21 – 265 VAC Input and Maximum Load.
Upper: I
Lower: V
, 0.5 A / div.
DRAIN
, 200 V & 1 ms / div.
DRAIN
11.4 Load Transient Response
In the figures shown below, signal averaging was used to better enable viewing the load
transient response. Since the output switching and line frequency occur essentially at
random with respect to the load transient, contributions to the output ripple from these
sources will average out, leaving the contribution only from the load step response.
Figure 22 – Transient Response, 115 VAC, +12 V
0.25 A-0.64 A-0.25 A Load Step. All
other outputs are at full load.
Bottom Trace: 5 V Output at 50 mV / div.
Next Trace: 3.3 V Output at 50 mV / div.
Next Trace: +12 V Output at 0.5 V / div.
Top Trace: -12 V Output at 0.5 V / div.
1 ms / div
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.
Figure 23 – Transient Response, 230 VAC, +12 V
0.25 A-0.64 A-0.25 A Load Step. All
other outputs are at full load.
Bottom Trace: 5V Output at 50 mV / div.
Next Trace: 3.3V Output at 50 mV / div.
Next Trace: +12 V Output at 0.5 V / div.
Top Trace: -12 V Output at 0.5 V / div.
1 ms / div.
22-May-07 RDR-115 7.5 W, 13 W pk Multi-Output DVD/Set-Top Box Supply
Figure 24– Transient Response, 230 VAC, +12 V
0.25 A-0.64 A-0.25 A Load Step. All
other outputs are at full load.
Bottom Trace: 5 V Output at 50 mV/div.
Next Trace: 3.3 V Output at 50 mV/div.
Next Trace: +12 V Output at 0.5 V/div.
Top Trace: -12 V Output at 0.5 V/div.
50 ms / div
.
Figure 25 – Transient Response, 230 VAC, +3.3 V
0.375 A-0.5 A-0.375 A Load Step. All
other outputs are at full load.
Bottom Trace: 5 V Output at 50 mV / div.
Next Trace: 3.3 V Output at 50 mV / div.
Next Trace: +12 V Output at 0.5 V / div.
Top Trace: -12 V Output at 0.5 V / div.
20 ms / div
.
Page 27 of 36
Figure 26 – Transient Response, 230 VAC, +5 V
0.375 A-0.5 A-0.375 A Load Step. All
other outputs are at full load.
Bottom Trace: 5 V Output at 50 mV / div.
Next Trace: 3.3 V Output at 50 mV / div.
Next Trace: +12 V Output at 0.5 V / div.
Top Trace: -12 V Output at 0.5 V / div.
20 ms / div
.
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Figure 27 – Transient Response, 115 VAC, +3.3 V
0.375 A-0.6 A-0.375 A Load Step. All
other outputs are at full load.
3.3 V Output at 10 mV / div.
50 ms / div
.
Figure 29 – Transient Response, 115 VAC, +5 V
0.375 A-0.6 A-0.375 A Load Step. All
other outputs are at full load.
5 V Output at 20 mV / div.
50 ms / div
.
Figure 28 – Transient Response, 230 VAC, +3.3 V
0.375 A-0.6 A-0.375 A Load Step. All
other outputs are at full load.
3.3 V Output at 10 mV / div.
50 ms / div
.
Figure 30 – Transient Response, 230 VAC, +5 V
0.375 A-0.6 A-0.375 A Load Step. All
other outputs are at full load.
5 V Output at 20 mV / div.
50 ms / div
.
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11.5 Output Ripple Measurements
11.5.1 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 31 and Figure 32.
The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe
tip. The capacitors include one (1) 0.1 µF/50 V ceramic type and one (1) 1.0 µF/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 31 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 32 – 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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11.5.2 Measurement Results
Figure 33 – 3.3 V Ripple, 115 VAC, Full Load.
2 ms, 50 mV / div.
Figure 35 – +12V Ripple, 115 VAC, Full Load.
2 ms, 50 mV /div.
Figure 34 – 5 V Ripple, 115 VAC, Full Load.
2 ms, 50 mV / div.
Figure 36 – -12 V Ripple, 115 VAC, Full Load.
2 ms, 50 mV /div.
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11.6 Line Surge
Differential input line 1.2/50 µs surge testing was completed on a single test unit to
IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load
and operation was verified following each surge event.
Surge
Level (V)
Input
Voltage
Injection
Location
Injection
Phase (°)
Test Result
(Pass/Fail)
(VAC)
+500 230 L to N 90 Pass
-500 230 L to N 90 Pass
+1000 230 L to N 90 Pass
-1000 230 L to N 90 Pass
+2000 230 L to N 90 Pass
-2000 230 L to N 90 Pass
+2000 230 L,N to G 90 Pass
-2000 230 L,N to G 90 Pass
Unit passes under all test conditions.
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12 Conducted EMI
Conducted EMI was tested at 115 VAC as well as 230 VAC. In both cases the output was
grounded.
Figure 37 –
Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55022 B Limits.
Figure 38 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55022 B Limits.
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13 Appendix A
13.1 Output Power Delivery Using a TNY375PN
The table below compares the output power delivery of the TNY375PN vs. TNY376PN.
No other modifications were made to the power supply. The measurements were taken
at room temperature in open air. The input voltage was 85 VAC. The Continuous Power
was measured when the source pin temperature stabilized at 71°C. This was the
temperature that the TNY376 reached when delivering 7.5 Watts in the environment
described above.
TNY375PN TNY376PN
Peak Power Capability (calculated)
Continuous Power Delivery
(for 50 ºC device temperature rise)
11.4 W 13 W
7.2 W 7.5 W
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14 Revision History
Date Author Revision Description & changes Reviewed
22-May-07 SGK 1.0 Initial publication
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Notes
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For the latest updates, visit our website:
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
LIMITATI ON, THE IMP LIED WARR ANTIES OF MER CHANT ABILITY , FITNE SS FOR A PARTIC ULAR P URPOS E, AND
NON-INFRINGEMENT 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 Lo go, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield,
Filterfuse, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trad emarks are property of
their respective companies. ©Copyright 2 007 Power Integrations, Inc.
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WORLD HEADQUARTERS
5245 Hellyer Avenue
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Main: +1-408-414-9200
Customer Service:
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