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TinySwitch-III
Design Highlights Schottky diode D7 and capacitor C8 rectify and filter the output.
• Simple, low cost, low parts count solution Inductors L3 and capacitor C9 attenuate the switching ripple on
• Low input power at no-load: <100 mW at 265 VAC the output. Capacitor C3 selects the standard current limit of U1.
• High efficiency >81% at 90 VAC For higher efficiency, the next larger (TNY280P) device may be
• Meets CEC 2008 requirements for active mode efficiency used. In this case, the value of C3 would be changed to 1 μF,
• (79 % vs. 74.4 % requirement) selecting the reduced current limit for the larger device, but no
• >10 dBμV margin to EN55022B conducted EMI limits other circuit changes would be required.
• Simple, primary-side output overvoltage latching shut- down
protects load under fault conditions The primary clamp (D5, R1, C5, R5 and R6) limits the maximum
• Low line frequency leakage current <10 μA peak drain voltage below the 700 V breakdown voltage of U1's
internal MOSFET. Resistor R1 dampens the high-frequency ringing
Operation of the T1 leakage inductance.
The TNY279 (U1) in the 8-pin DIP package selected for the flyback
design in Figure 1 is ideal for adapter applications. The arrange- The built-in frequency jitter and E-ShieldTM techniques allow simple
ment of the four SOURCE pins on one side of the package allows EMI filtering to comply with EN55022B. Resistor R2 and C4 form
a small metal heatsink to be inserted. This allows the device to an RC snubber to reduce high-frequency EMI.
operate in a sealed adapter with an external ambient of 40 °C.
Output overvoltage protection (OVP) is provided on the primary
The internal MOSFET in U1 conducts current through the primary side by sensing the voltage of the auxiliary transformer winding.
winding of T1 during each enabled switching cycle. When the Should the main feedback loop open due to failure of U2, then U1
primary current reaches the MOSFET current limit, the controller will latch off once the current into the BP/M pin (via VR3) exceeds
turns it off, and the energy in T1 is transferred to the output. 6.5 mA. Diode D6 and capacitor C7 rectify and smooth the
C6 C11
68 pF 1 nF R7
250 VAC 100 V 20 Ω
C5 L3
L4 1 nF R5 R6 Ferrite Bead
1 mH 1 kV 240 kΩ 240 kΩ T1 3.5 × 7.6 mm +12 V, 1.25 A
1 10
C8 C9
D7 680 μF 220 μF
D1 D2 SB580
1N4005GP 1N4005 3 9 25 V 25 V
F1 NC
3.15 A 5 RTN
C1 C2
10 μF 22 μF R1 D6
400 V 400 V 100 Ω 1N4148
90-265 4
VAC
D5 EF20 C7 R8
FR107 1 μF 56 Ω
50 V
D3 D4 VR3
1N4005GP 1N4005 BZX79-B6V8
L5 6.8 V
3.3 μH
R4 R9
U2-B 1 kΩ
TinySwitch-III 47 Ω
R11
U1 39 kΩ
TNY279PN 1%
R3
10 kΩ
D
EN/UV
R2 C10 R10
BP/M
100 Ω S 220 nF 3 kΩ
S 50 V
C3 U2-A U3
C4 LM431
33 pF 100 nF PC817A R12
1 kV 50 V 10 kΩ
1%
PI-4417-122007
Figure 1. 15 W, 12 W Output Supply Using TNY279P.
PI-4415-050806
Winding Details
Bias: 5T, 4 × 28 AWG
30 12 V: 7T, 23 AWG T.I.W.
3 mm tape margin, Shield (1-NC), tape,
Winding Order
25 Primary (3-1), tape, Bias (5-4), tape,
(pin numbers)
12 V (10-9), tape
20 Primary: 790 μH, ±7%
Voltage (V)
Inductance
Leakage: 30 μH (maximum)
15
Primary Resonant 650 kHz (minimum)
Frequency
10
Table 1. Transformer Parameters. (AWG = American Wire Gauge, TIW = Triple
Insulated Wire, NC = No Connection)
5
-5
0 50 100
Time (ms)
Figure 2. Worst-Case Open Loop Output Overvoltage
(85 VAC, Full Load).
Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2006, Power Integrations, Inc.
C
02/08 DI-117
DI-130 Design Idea
®
TinySwitch-III
Design Highlights the current limit set-point threshold, U1 drives U3 on. The photo-
• Very high efficiency: ≥82% transistor in U3 pulls current out of the EN/UV pin of U2, causing it
• Low component count: only 40 parts to skip switching cycles. Once the output current drops below the
• No common-mode choke required to meet EN55022B current limit set-point threshold, U1 stops driving U3, which stops
conducted EMI requirements pulling current out of the EN/UV pin of U2, and switching cycles
• Valley Fill circuit allows supply to meet IEC61000-3-2 THD limits are enabled again. The TL431 (U4) provides a reference for U1 to
• ON/OFF control rejects the high line ripple voltage caused by compare against the voltage drop across R11.
the Valley Fill (THD correction) circuit
The output diode (D9) is located in the lower leg of the transformer
Operation (T1) secondary winding to reduce EMI noise generation. An RCD
The flyback converter shown in Figure 1 uses a member of the clamp (R16, C4 and D13) protects the drain node of the MOSFET
TinySwitch-III family (U2, a TNY279PN) to provide up to 1.8 A of from the flyback voltage spike.
load current to six, high-intensity, Luxeon LEDs (the LXHL series).
The Valley Fill circuit (D5, D6, D7, C15, C16 and R15) limits the
The output voltage is slightly below the forward voltage drop of the values of the third and fifth harmonics of the line frequency current,
LEDs. Therefore, when the LEDs are connected to the supply, it which enables this supply to meet the requirements for Total
operates in constant current (CC) mode. If the LEDs are discon- Harmonic Distortion (THD) specified in IEC61000-3-2.
nected from the supply, Zener diode VR1 provides voltage
feedback, which regulates the output voltage at about 13.5 VDC. The frequency jittering function in U2, a shield winding in T1 and a
A 100 mΩ resistor (R11) senses the output current and an Opamp Y class capacitor (C8) across T1 reduce the generation of
(U1) drives the optocoupler (U3), which provides feedback to U2. conducted EMI so that a simple pi filter (C13, L1, L2 and C14)
The TinySwitch-III family of devices regulate by disabling or allows the supply to meet EN55022B limits.
skipping MOSFET switching cycles. As the load current reaches
C8
2.2 nF
250 VAC
C6 C7
680 μF 680 μF
35 V 35 V 10 V, 1.8 A
1 10
Figure 1. Circuit Diagram of a Passive PFC Power Supply for Driving Lighting LEDs.
86
PI-4525-110606
84
82
Efficiency (%)
80
100% Figure 3. Input Voltage (100 V/div) and Current (100 mA/div), Showing
78 75% the Effect of the Valley Fill Circuit.
50%
76 25%
74 Transformer Parameters
72 Core Material PC40EF25-Z
Bobbin EF25 Horizontal bobbin
70
185 195 205 215 225 235 245 255 265 Primary: 92T, 0.3 mm heavy nyleze magnet wire
Winding Details
Secondary: 14T 2 × 0.4 mm T.I.W., tape
Input Voltage (VAC)
Winding Order
Figure 2. Efficiency vs Input Voltage at Different Load Levels, Room Temperature, Primary (2–4), Secondary (6–10)
(pin numbers)
50 Hz Line.
Inductance 1.6 mH
Table 1. Transformer Parameters. (AWG = American Wire Gauge, TIW = Triple
Insulated Wire, NC = No Connection)
Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2006, Power Integrations, Inc.
B
12/07 DI-130
DI-176 Design Idea
®
TinySwitch-III
Design Highlights
• Simple, low part-count design The TNY279PN device is used in a flyback topology. During the on
• Very high efficiency: >80% over line voltage time of U1’s internal MOSFET, current rises linearly in the primary
• One isolated and one primary referenced output ideal for white winding of transformer T1. While current builds in the primary,
good applications energy is stored in the transformer. Once the current through the
• Hysteretic thermal shutdown MOSFET reaches the device’s current limit, or DCMAX is reached, the
MOSFET turns off. The flyback portion of the conduction cycle now
Operation begins. During this period a voltage is induced in the secondary
The TinySwitch-III supply shown in Figure 1 provides 20 W of winding, and the energy stored in the transformer is transferred to
output power. The 15 V output is capable of delivering up to the output capacitors and the load.
50 mA of current and is typically used to supply the primary side
driver for a brushless DC (BLDC) motor as it is referenced to the During the supply’s flyback period, an RCD snubber circuit keeps the
source of the MOSFET internal to U1 (primary side). The 12 V voltage at the drain node below the device’s BVDSS limit. The snubber
regulated isolated output, delivering up to 1.6 A, can be used to circuit is comprised of fast-blocking diode D1, capacitor C2, and
drive a microcontroller, relays, and a stepper motor. resistor R1.
The supply uses a large input capacitor, C1, to maintain a Diode D2 rectifies the 15 V secondary output while capacitor C4
constant voltage source for the BLDC motor. It is assumed that filters and smoothes. Inductor L1, and capacitors C6 and C7 all
this supply will be placed after all necessary EMI filtering and AC form a post filter, helping to eliminate switching frequency ripple.
rectification, and thus none of these components are shown. Resistor R2 acts as a preload and improves regulation at no load.
However, Y-capacitor C10 is shown as part of the EMI filtering that
may be necessary.
D3
UG4D L2
T1 12 MH
EE22 2A 12 V, 1.6 A
2 6
D4 C5 C8 C9
UG4D 1000 MF 1000 MF 0.1 MF
R1 C2 35 V 25 V
7
82 k7 10 nF
2W 630V D2 L1 ISO_RTN
UG2D 12 MH 15 V, 50 mA
4
10
C4 C6 C7 R2
470 MF 330 MF 0.1 MF 700 7
D1 25 V 25 V 1/2 W
1N4937 9
C1
200 - 400 330 MF PRI_RTN
VDC 450 V R3
TinySwitch-III
U1 220 7
D
TNY279PN
EN/UV
BP
U2B U2A R4
S PC817A 1 k7
C3 PC817A
10 MF
50V
C10 VR1
4.7 nF BZX55C11
250 VAC 11 V
PI-5010-032808
Output regulation is achieved using the TinySwitch-III’s On/Off device size to be optimized for the thermal environment. For
control scheme. At the leading edge of each internal clock cycle, example, for this design, the TNY280PN part could be used by
the current out of the EN/UV pin is sampled. If this current is in changing bypass capacitor C3 from 10 μF to 0.1 μF.
• Dual diodes (D3 and D4) reduce losses and improve efficiency.
excess of 115 μA, then the subsequent switching cycle is disabled
(skipped) for this period, otherwise the cycle is enabled. During However, single diode use is acceptable electrically.
each clock cycle this process is repeated. By adjusting the ratio of
Transformer Parameters
90
PI-5011-022708
PC40EE22-Z or equivalent, gapped for ALG of
Core Material
127 nH/t²
Bobbin EE22, Vertical
Efficiency (%)
0.4
0.2
0
265 325 390
Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2008, Power Integrations, Inc.
A
03/08 DI-176
DI-177 Design Idea
®
TinySwitch-III
3 6
D1-D4 D5 4 RTN
F1 1N4007 1N4007GP VR2
3.15 A C6 1N5237B
C1 C2 D6 8.2 V
10 MF 10 MF 5 1 MF BAV20
165 - 265 C9 400 V 400 V 50 V
VAC 47 nF T1
275 VAC EF20 R6
R7 240 7
TinySwitch-III 30 k7
U3 D
TNY279PN EN/UV
BP/M
PI-5013-032808
S
U2
C5 PC817A
1 MF
L1 50 V
1000 MH
Figure 1: Schematic of 9 W Power Supply Using a TNY279PN in High Ambient Temperature Applications.
www.powerint.com March 2008
no-load and standby. Resistor R2 damps excessive ringing, thereby Key Design Points
improving EMI margin. • To improve efficiency, a larger device than required for power
delivery was selected.
The output is rectified by diode D7 and filtered by low ESR • Resistor R2 allows the use of a slow, low cost rectifier diode by
capacitor C7. Post filtering (L2 and C8) further reduces switching limiting the reverse current through D5 when U3 turns on. The
ripple and noise on the main output. selection of a slow diode also improves conducted EMI
immunity, but the diode should be a glass-passivated type with
The bias winding is also used to supply current to U3’s BP/M pin a recovery time of ≤2 μs. If glass passivated (1N4007GP) is
during steady state operation. The value of R7 is selected to unavailable, an FR107 may be used.
deliver the IC supply current to the BP/M pin, thereby inhibiting the • Resistor R8 and capacitor C10 form the secondary snubber
internal high-voltage current source that normally charges the and help to reduce high frequency (radiated) EMI.
BP/M pin capacitor (C5). This results in reduced input power • Thermal design of the supply should be made such that the
consumption under light load and no load conditions. hottest component on the board is U3. The hysteretic tempera-
ture shutdown feature of U3 can thus ensure that overall
90 temperature of the board is within acceptable limits.
PI-5014-031008
88
PI-5016-031008
86
82
110
80
78
105
76
74
100
72
70 95
155 175 195 215 235 255 275
Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2008, Power Integrations, Inc.
A
03/08 DI-177