Power integrations TinySwitch-III, TNY275G, TNY274P, TNY276P, TNY275P Series Manual

...
TNY274-280
PI-4095-082205
Wide-Range HV DC Input
D
S
EN/UV
BP/M
+
-
+
-
DC
Output
TinySwitch-III
®
TinySwitch-III Family
Energy Efficient, Off-Line Switcher with Enhanced Flexibility and Extended Power Range
Product Highlights
Lowest System Cost with Enhanced Flexibility
• Simple ON/OFF control, no loop compensation needed
- Higher current limit extends peak power or, in open frame applications, maximum continuous power
- Lower current limit improves efficiency in enclosed adapters/chargers
- Allows optimum TinySwitch-III choice by swapping devices with no other circuit redesign
• Tight I2f parameter tolerance reduces system cost
- Maximizes MOSFET and magnetics power delivery
- Minimizes max overload power, reducing cost of transformer, primary clamp & secondary components
• ON-time extension – extends low line regulation range/ hold-up time to reduce input bulk capacitance
• Self-biased: no bias winding or bias components
• Frequency jittering reduces EMI filter costs
• Pin-out simplifies heatsinking to the PCB
• SOURCE pins are electrically quiet for low EMI
Enhanced Safety and Reliability Features
• Accurate hysteretic thermal shutdown protection with automatic recovery eliminates need for manual reset
• Improved auto-restart delivers <3% of maximum power in short circuit and open loop fault conditions
• Output overvoltage shutdown with optional Zener
• Line under-voltage detect threshold set using a single optional resistor
• Very low component count enhances reliability and enables single-sided printed circuit board layout
• High bandwidth provides fast turn on with no overshoot and excellent transient load response
• Extended creepage between DRAIN and all other pins improves field reliability
Figure 1. Typical Standby Application.
OUTPUT POWER TABLE
230 VAC ±15% 85-265 VAC
PRODUCT
TNY274 P or G 6 W 11 W 5 W 8.5 W TNY275 P or G TNY276 P or G TNY277 P or G TNY278 P or G 16 W 28 W 10 W 21.5 W TNY279 P or G TNY280 P or G
Table 1. Notes: 1. Minimum continuous power in a typical non- ventilated enclosed adapter measured at 50 external heatsink will increase power capability power capability in any design or minimum continuous power in an open frame design (see Key Application Considerations). 3. Packages: P: DIP-8C, G: SMD-8C. See Part Ordering Information.
3
Adapter
8.5 W 15 W 6 W 11.5 W 10 W 19 W 7 W 15 W 13 W 23.5 W 8 W 18 W
18 W 32 W 12 W 25 W 20 W 36.5 W 14 W 28.5 W
Peak or
1
Open
Frame
Peak or
Adapter
2
°C ambient. Use of an
1
Open
Frame
2. Minimum peak
2
EcoSmart®– Extremely Energy Efficient
• Easily meets all global energy efficiency regulations
• No-load <150 mW at 265 VAC without bias winding, <50 mW with bias winding
• ON/OFF control provides constant efficiency down to very light loads – ideal for mandatory CEC regulations and 1 W PC standby requirements
Applications
• Chargers/adapters for cell/cordless phones, PDAs, digital cameras, MP3/portable audio, shavers, etc.
February 2006
• PC Standby and other auxiliary supplies
• DVD/PVR and other low power set top decoders
• Supplies for appliances, industrial systems, metering, etc.
Description
TinySwitch-III incorporates a 700 V power MOSFET, oscillator, high voltage switched current source, current limit (user selectable) and thermal shutdown circuitry. The IC family uses an ON/OFF control scheme and offers a design flexible solution with a low system cost and extended power capability.
TNY274-280
PI-4077-013106
CLOCK
OSCILLATOR
5.85 V
4.9
V
SOURCE
(S)
SRQ
DC
MAX
BYPASS/
MULTI-FUNCTION
(BP/M)
+
-
V
I
LIMI
T
FAULT
PRESENT
CURRENT LIMIT COMP
ARATOR
ENABLE
LEADING
EDGE
BLANKING
THERMAL
SHUTDOWN
+
-
DRAIN
(D)
REGULATOR
5.85
V
BYPASS PIN UNDER-VOL
TAGE
1.0 V + V
T
ENABLE/
UNDER-
VOLTAGE
(EN/UV)
Q
115 µA 25 µA
LINE UNDER-VOLTAGE
RESET
AUTO­RESTART COUNTER
JITTER
1.0 V
6.4
V
CURRENT
LIMIT STAT
E
MACHINE
PI-4078-080905
D
S
BP/
M
S
S
EN/UV
P Package (DIP-8C)
G Package (SMD-8C)
8
5
7
1
4
2
S
6
Figure 2. Functional Block Diagram.
Pin Functional Description
DRAIN (D) Pin:
This pin is the power MOSFET drain connection. It provides internal operating current for both start-up and steady-state operation.
BYPASS/MULTI-FUNCTION (BP/M) Pin:
This pin has multiple functions:
1. It is the connection point for an external bypass capacitor for the internally generated 5.85 V supply.
2. It is a mode selector for the current limit value, depending on the value of the capacitance added. Use of a 0.1 capacitor results in the standard current limit value. Use of a 1 µF capacitor results in the current limit being reduced to that of the next smaller device size. Use of a 10 µF capacitor results in the current limit being increased to that of the next larger device size for TNY275-280.
3. It provides a shutdown function. When the current into the bypass pin exceeds 5.5 mA, the device latches off until the BP/M voltage drops below 4.9 V, during a power down. This can be used to provide an output overvoltage function
2
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µF
Figure 3. Pin Configuration.
with a Zener connected from the BP/M pin to a bias winding supply.
ENABLE/UNDER-VOLTAGE (EN/UV) Pin:
This pin has dual functions: enable input and line under-voltage sense. During normal operation, switching of the power
TNY274-280
600
0 5
10
136 kHz
128 kHz
V
DRAIN
Time (µs)
PI-2741-041901
500
400
300
200
100
0
MOSFET is controlled by this pin. MOSFET switching is terminated when a current greater than a threshold current is drawn from this pin. Switching resumes when the current being pulled from the pin drops to less than a threshold current. A modulation of the threshold current reduces group pulsing. The threshold current is between 60 µA and 115 µA.
The EN/UV pin also senses line under-voltage conditions through an external resistor connected to the DC line voltage. If there is no external resistor connected to this pin, TinySwitch-III detects its absence and disables the line under-voltage function.
SOURCE (S) Pin:
This pin is internally connected to the output MOSFET source for high voltage power return and control circuit common.
TinySwitch-III Functional Description
TinySwitch-III combines a high voltage power MOSFET switch with a power supply controller in one device. Unlike conventional PWM (pulse width modulator) controllers, it uses a simple ON/OFF control to regulate the output voltage.
The controller consists of an oscillator, enable circuit (sense and logic), current limit state machine, 5.85 V regulator, BYPASS/ MULTI-FUNCTION pin under-voltage, overvoltage circuit, and current limit selection circuitry, over- temperature protection, current limit circuit, leading edge blanking, and a 700 V power MOSFET. TinySwitch-III incorporates additional circuitry for line under-voltage sense, auto-restart, adaptive switching cycle on-time extension, and frequency jitter. Figure 2 shows the functional block diagram with the most important features.
Oscillator
The typical oscillator frequency is internally set to an average of 132 kHz. Two signals are generated from the oscillator: the
maximum duty cycle signal (DC
) and the clock signal that
MAX
indicates the beginning of each cycle.
The oscillator incorporates circuitry that introduces a small amount of frequency jitter, typically 8 kHz peak-to-peak, to minimize EMI emission. The modulation rate of the frequency jitter is set to 1 kHz to optimize EMI reduction for both average and quasi-peak emissions. The frequency jitter should be measured with the oscilloscope triggered at the falling edge of the DRAIN waveform. The waveform in Figure 4 illustrates the frequency jitter.
Enable Input and Current Limit State Machine
The enable input circuit at the EN/UV pin consists of a low impedance source follower output set at 1.2 V. The current through the source follower is limited to 115
µA. When the
current out of this pin exceeds the threshold current, a low logic level (disable) is generated at the output of the enable circuit, until the current out of this pin is reduced to less than the threshold current. This enable circuit output is sampled at the beginning of each cycle on the rising edge of the clock signal. If high, the power MOSFET is turned on for that cycle (enabled). If low, the power MOSFET remains off (disabled). Since the sampling is done only at the beginning of each cycle, subsequent changes in the EN/UV pin voltage or current during the remainder of the cycle are ignored.
The current limit state machine reduces the current limit by discrete amounts at light loads when TinySwitch-III is likely to switch in the audible frequency range. The lower current limit raises the effective switching frequency above the audio range and reduces the transformer flux density, including the associated audible noise. The state machine monitors the sequence of enable events to determine the load condition and adjusts the current limit level accordingly in discrete amounts.
Under most operating conditions (except when close to no-load), the low impedance of the source follower keeps the voltage on the EN/UV pin from going much below 1.2 V in the disabled state. This improves the response time of the optocoupler that is usually connected to this pin.
Figure 4. Frequency Jitter.
5.85 V Regulator and 6.4 V Shunt Voltage Clamp
The 5.85 V regulator charges the bypass capacitor connected to the BYPASS pin to 5.85 V by drawing a current from the voltage on the DRAIN pin whenever the MOSFET is off. The BYPASS/MULTI-FUNCTION pin is the internal supply voltage node. When the MOSFET is on, the device operates from the energy stored in the bypass capacitor. Extremely low power consumption of the internal circuitry allows TinySwitch-III to operate continuously from current it takes from the DRAIN pin. A bypass capacitor value of 0.1
µF is sufficient for both
high frequency decoupling and energy storage.
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TNY274-280
PI-4098-082305
0
2500 5000
Time (ms)
0
5
0
10
100
200
300
V
DRAIN
V
DC-OUTPUT
In addition, there is a 6.4 V shunt regulator clamping the BYPASS/MULTI-FUNCTION pin at 6.4 V when current is provided to the BYPASS/MULTI-FUNCTION pin through an external resistor. This facilitates powering of TinySwitch-III externally through a bias winding to decrease the no-load consumption to well below 50 mW.
BYPASS/MULTI-FUNCTION Pin Under-Voltage
The BYPASS/MULTI-FUNCTION pin under-voltage circuitry disables the power MOSFET when the BYPASS/MULTI­FUNCTION pin voltage drops below 4.9 V in steady state operation. Once the BYPASS/MULTI-FUNCTION pin voltage drops below 4.9 V in steady state operation, it must rise back to 5.85 V to enable (turn-on) the power MOSFET.
Over Temperature Protection
The thermal shutdown circuitry senses the die temperature. The threshold is typically set at 142 °C with 75 °C hysteresis. When the die temperature rises above this threshold the power MOSFET is disabled and remains disabled until the die temperature falls by 75 °C, at which point it is re-enabled. A large hysteresis of 75 °C (typical) is provided to prevent overheating of the PC board due to a continuous fault condition.
Current Limit
The current limit circuit senses the current in the power MOSFET. When this current exceeds the internal threshold (I
LIMIT
), the power MOSFET is turned off for the remainder of that cycle. The current limit state machine reduces the current limit threshold by discrete amounts under medium and light loads.
The leading edge blanking circuit inhibits the current limit comparator for a short time (t
) after the power MOSFET is
LEB
turned on. This leading edge blanking time has been set so that current spikes caused by capacitance and secondary-side rectifier reverse recovery time will not cause premature termination of the switching pulse.
Auto-Restart
In the event of a fault condition such as output overload, output short circuit, or an open loop condition, TinySwitch-III enters into auto-restart operation. An internal counter clocked by the oscillator is reset every time the EN/UV pin is pulled low. If the EN/UV pin is not pulled low for 64 ms, the power MOSFET switching is normally disabled for 2.5 seconds (except in the case of line under-voltage condition, in which case it is disabled until the condition is removed). The auto-restart alternately enables and disables the switching of the power MOSFET until the fault condition is removed. Figure 5 illustrates auto-restart circuit operation in the presence of an output short circuit.
In the event of a line under-voltage condition, the switching of the power MOSFET is disabled beyond its normal 2.5 seconds until the line under-voltage condition ends.
Adaptive Switching Cycle On-Time Extension
Adaptive switching cycle on-time extension keeps the cycle on until current limit is reached, instead of prematurely terminating after the DC
signal goes low. This feature
MAX
reduces the minimum input voltage required to maintain regulation, extending hold-up time and minimizing the size of bulk capacitor required. The on-time extension is disabled during the startup of the power supply, until the power supply output reaches regulation.
Line Under-Voltage Sense Circuit
The DC line voltage can be monitored by connecting an external resistor from the DC line to the EN/UV pin. During power-up or when the switching of the power MOSFET is disabled in auto­restart, the current into the EN/UV pin must exceed 25
µA to
initiate switching of the power MOSFET. During power-up, this is accomplished by holding the BYPASS/MULTI-FUNCTION pin to 4.9 V while the line under-voltage condition exists. The BYPASS/MULTI-FUNCTION pin then rises from 4.9 V to
5.85 V when the line under-voltage condition goes away. When the switching of the power MOSFET is disabled in auto-restart mode and a line under-voltage condition exists, the auto-restart counter is stopped. This stretches the disable time beyond its normal
2.5 seconds until the line under-voltage condition ends.
Figure 5. Auto-Restart Operation.
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The line under-voltage circuit also detects when there is no external resistor connected to the EN/UV pin (less than ~1 µA into the pin). In this case the line under-voltage function is disabled.
TinySwitch-III Operation
TinySwitch-III devices operate in the current limit mode. When enabled, the oscillator turns the power MOSFET on at the beginning of each cycle. The MOSFET is turned off when the current ramps up to the current limit or when the DC
MAX
limit is reached. Since the highest current limit level and frequency of a TinySwitch-III design are constant, the power delivered to the
TNY274-280
V
DRAI
N
V
EN
CLOCK
DC
DRAI
N
I
MAX
PI-2749-082305
V
DRAI
N
V
EN
CLOCK
DC
DRAI
N
I
MAX
PI-2667-082305
PI-2377-082305
V
DRAI
N
V
EN
CLOCK
DC
DRAI
N
I
MAX
load is proportional to the primary inductance of the transformer and peak primary current squared. Hence, designing the supply involves calculating the primary inductance of the transformer for the maximum output power required. If the TinySwitch-III is appropriately chosen for the power level, the current in the calculated inductance will ramp up to current limit before the DC
limit is reached.
MAX
Enable Function
TinySwitch-III senses the EN/UV pin to determine whether or
Figure 6. Operation at Near Maximum Loading.
not to proceed with the next switching cycle. The sequence of cycles is used to determine the current limit. Once a cycle is started, it always completes the cycle (even when the EN/UV pin changes state half way through the cycle). This operation results in a power supply in which the output voltage ripple is determined by the output capacitor, amount of energy per switch cycle and the delay of the feedback.
The EN/UV pin signal is generated on the secondary by comparing the power supply output voltage with a reference voltage. The EN/UV pin signal is high when the power supply output voltage is less than the reference voltage.
In a typical implementation, the EN/UV pin is driven by an optocoupler. The collector of the optocoupler transistor is connected to the EN/UV pin and the emitter is connected to the SOURCE pin. The optocoupler LED is connected in series with a Zener diode across the DC output voltage to be regulated. When the output voltage exceeds the target regulation voltage level (optocoupler LED voltage drop plus Zener voltage), the optocoupler LED will start to conduct, pulling the EN/UV pin low. The Zener diode can be replaced by a TL431 reference circuit for improved accuracy.
ON/OFF Operation with Current Limit State Machine
The internal clock of the TinySwitch-III runs all the time. At the beginning of each clock cycle, it samples the EN/UV pin to decide whether or not to implement a switch cycle, and based on the sequence of samples over multiple cycles, it determines the appropriate current limit. At high loads, the state machine sets the current limit to its highest value. At lighter loads, the state machine sets the current limit to reduced values.
Figure 7. Operation at Moderately Heavy Loading.
Figure 8. Operation at Medium Loading.
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TNY274-280
PI-2661-082305
V
DRAI
N
V
EN
CLOCK
DC
DRAIN
I
MAX
PI-2395-030801
0
2.5 5
Time (s)
0
100
200
400
300
0
100
200
V
DC-INPUT
V
DRAIN
0
1 2
Time (ms)
0
200
400
5
0
10
0
100
200
PI-2383-030801
V
DC-INPUT
V
BYPASS
V
DRAIN
PI-2381-1030801
0
1 2
Time (ms)
0
200
400
5
0
10
0
100
200
V
DC-INPUT
V
BYPASS
V
DRAIN
PI-2348-030801
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.5 1
Time (s)
0
100
200
300
0
100
200
400
V
DC-INPUT
V
DRAIN
Figure 9. Operation at Very Light Load.
Figure 11. Power-Up Without Optional External UV Resistor Connected to EN/UV Pin.
At near maximum load, TinySwitch-III will conduct during nearly all of its clock cycles (Figure 6). At slightly lower load, it will “skip” additional cycles in order to maintain voltage regulation at the power supply output (Figure 7). At medium loads, cycles will be skipped and the current limit will be reduced (Figure 8). At very light loads, the current limit will be reduced even further (Figure 9). Only a small percentage of cycles will occur to satisfy the power consumption of the power supply.
The response time of the ON/OFF control scheme is very fast compared to PWM control. This provides tight regulation and excellent transient response.
Figure 12. Normal Power-Down Timing (without UV).
Figure 10. Power-Up with Optional External UV Resistor (4 M) Connected to EN/UV Pin.
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Figure 13. Slow Power-Down Timing with Optional External (4 M
) UV Resistor Connected to EN/UV Pin.
TNY274-280
Power Up/Down
The TinySwitch-III requires only a 0.1 µF capacitor on the BYPASS/MULTI-FUNCTION pin to operate with standard current limit. Because of its small size, the time to charge this capacitor is kept to an absolute minimum, typically 0.6 ms. The time to charge will vary in proportion to the BYPASS/MULTI­FUNCTION pin capacitor value when selecting different current limits. Due to the high bandwidth of the ON/OFF feedback, there is no overshoot at the power supply output. When an external resistor (4 M) is connected from the positive DC input to the EN/UV pin, the power MOSFET switching will be delayed during power-up until the DC line voltage exceeds the threshold (100 V). Figures 10 and 11 show the power-up timing waveform in applications with and without an external resistor (4 M) connected to the EN/UV pin.
Under startup and overload conditions, when the conduction time is less than 400 ns, the device reduces the switching frequency to maintain control of the peak drain current.
During power-down, when an external resistor is used, the power MOSFET will switch for 64 ms after the output loses regulation. The power MOSFET will then remain off without any glitches since the under-voltage function prohibits restart when the line voltage is low.
Figure 12 illustrates a typical power-down timing waveform. Figure 13 illustrates a very slow power-down timing waveform as in standby applications. The external resistor (4 M
) is
connected to the EN/UV pin in this case to prevent unwanted restarts.
No bias winding is needed to provide power to the chip because it draws the power directly from the DRAIN pin (see
Functional Description above). This has two main benefits. First, for a nominal application, this eliminates the cost of a bias winding and associated components. Secondly, for battery charger applications, the current-voltage characteristic often allows the output voltage to fall close to zero volts while still delivering power. TinySwitch-III accomplishes this without a forward bias winding and its many associated components. For applications that require very low no-load power consumption (50 mW), a resistor from a bias winding to the BYPASS/ MULTI-FUNCTION pin can provide the power to the chip. The minimum recommended current supplied is 1 mA. The BYPASS/MULTI-FUNCTION pin in this case will be clamped at 6.4 V. This method will eliminate the power draw from the DRAIN pin, thereby reducing the no-load power consumption and improving full-load efficiency.
Current Limit Operation
Each switching cycle is terminated when the DRAIN current reaches the current limit of the device. Current limit operation provides good line ripple rejection and relatively constant power delivery independent of input voltage.
BYPASS/MULTI-FUNCTION Pin Capacitor
The BYPASS/MULTI-FUNCTION pin can use a ceramic capacitor as small as 0.1
µF for decoupling the internal power
supply of the device. A larger capacitor size can be used to adjust the current limit. For TNY275-280, a 1 µF BP/M pin capacitor will select a lower current limit equal to the standard current limit of the next smaller device and a 10 µF BP/M pin capacitor will select a higher current limit equal to the standard current limit of the next larger device. The higher current limit level of the TNY280 is set to 850 mA typical. The TNY274 MOSFET does not have the capability for increased current limit so this feature is not available in this device.
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TNY274-280
D
S
S
BP/M
EN/UV
L1
1 mH
D1
1N4007
RV1
275 VAC
F1
3.15 A
D2
1N4007
C1
6.8 µF 400 V
C6 1 µF 60 V
C2 22 µF 400 V
C10
1000 µF
25 V
C5
2.2 nF
250 VAC
C11
100
µF
25
V
+12 V, 1
A
85-265
VA
C
RTN
J4
J3
J1
J2
C7
100 nF
50 V
U1
TNY278P
C4
10 nF
1 kV
VR1
P6KE150A
NC 8
6
4
T1
2
5
1
3
D5
1N4007GP
D6
UF4003
D7
BYV28-200
U2
PC817A
VR2
1N5255B
28 V
VR3
BZX79-C11
11 V
C7 is configurable to adjust U1 current limit, see circuit description
*R5 and R8 are optional components
R5*
3.6 M
R3
47
1/8
W
R4
2 k
1/8
W
R6 390 1/8
W
R7
20
R8*
21 k
1%
R1
1 k
R2
100
D3
1N4007
D4
1N4007
L2
Ferrite Bead
3.5 × 7.6 mm
PI-4244-021406
TinySwitch-III
Figure 14. TNY278P, 12 V, 1 A Universal Input Power Supply.
Applications Example
The circuit shown in Figure 14 is a low cost, high efficiency, flyback power supply designed for 12 V, 1 A output from universal input using the TNY278.
The supply features under-voltage lockout, primary sensed output overvoltage latching shutdown protection, high efficiency (>80%), and very low no-load consumption (<50 mW at 265 VAC). Output regulation is accomplished using a simple zener reference and optocoupler feedback.
The rectified and filtered input voltage is applied to the primary winding of T1. The other side of the transformer primary is driven by the integrated MOSFET in U1. Diode D5, C2, R1, R2, and VR1 comprise the clamp circuit, limiting the leakage inductance turn-off voltage spike on the DRAIN pin to a safe value. The use of a combination a Zener clamp and parallel RC optimizes both EMI and energy efficiency. Resistor R2 allows the use of a slow recovery, low cost, rectifier diode by limiting the reverse current through D5. The selection of a slow diode also improves efficiency and conducted EMI but should be a glass passivated type, with a specified recovery time of 2 µs.
The output voltage is regulated by the Zener diode VR3. When the output voltage exceeds the sum of the Zener and optocoupler
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LED forward drop, current will flow in the optocoupler LED. This will cause the transistor of the optocoupler to sink current. When this current exceeds the ENABLE pin threshold current the next switching cycle is inhibited. When the output voltage falls below the feedback threshold, a conduction cycle is allowed to occur and, by adjusting the number of enabled cycles, output regulation is maintained. As the load reduces, the number of enabled cycles decreases, lowering the effective switching frequency and scaling switching losses with load. This provides almost constant efficiency down to very light loads, ideal for meeting energy efficiency requirements.
As the TinySwitch-III devices are completely self-powered, there is no requirement for an auxiliary or bias winding on the transformer. However by adding a bias winding, the output overvoltage protection feature can be configured, protecting the load against open feedback loop faults.
When an overvoltage condition occurs, such that bias voltage exceeds the sum of VR2 and the BYPASS/MULTIFUNCTION (BP/M) pin voltage (28 V+5.85 V), current begins to flow into the BP/M pin. When this current exceeds 5 mA the internal latching shutdown circuit in TinySwitch-III is activated. This condition is reset when the BP/M pin voltage drops below 2.6 V after removal of the AC input. In the example shown, on opening the loop, the OVP trips at an output of 17 V.
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