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| Design Example Report Title Specification Application Author Document Number Date Revision 3.7W Power Supply Using TNY263P Input: 80 - 288 VAC Output: 5V/300mA, 22V/100mA LCD TV Standby Power Integrations Applications Department DER-41 November 18, 2004 1.0 Summary and Features * * * * Extremely low (< 25 mW) No Load Power Consumption at 288VAC Low EMI for low signal interference Very good EMI margin with respect to EN55022 B limits with no Y-cap, no Xcap, no common mode choke Low cost and simple design for two output power supply 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-41 5V and 22V LCD TV Standby PS November 18, 2004 Table Of Contents 1 2 3 4 5 Introduction .................................................................................................................3 Photograph .................................................................................................................3 Power Supply Specification ........................................................................................4 Schematic ...................................................................................................................5 Circuit Description.......................................................................................................6 5.1 Input Rectification ................................................................................................6 5.2 Auxiliary Bias Supply and the 22V Primary Output ..............................................6 5.3 Primary DRAIN Voltage Clamp Circuit.................................................................6 5.4 Output Rectification and Filtering.........................................................................6 5.5 Output Voltage Sensing and Feedback ...............................................................6 6 PCB Layout.................................................................................................................7 7 Bill Of Materials...........................................................................................................8 8 Transformer Specification ...........................................................................................9 8.1 Electrical Diagram................................................................................................9 8.2 Electrical Specifications .......................................................................................9 8.3 Materials ..............................................................................................................9 8.4 Transformer Build Diagram................................................................................10 8.5 Transformer Construction ..................................................................................10 9 Transformer Spreadsheets .......................................................................................11 10 Performance Data .................................................................................................14 10.1 Line and Load Regulation..................................................................................14 10.2 Efficiency ...........................................................................................................14 10.3 No-Load and Minimum Load Input Power .........................................................15 10.4 Overload Protection ...........................................................................................15 11 Thermal Performance............................................................................................16 12 Waveforms ............................................................................................................17 12.1 Drain Voltage Normal Operation........................................................................17 12.2 Output Voltage Start-up Profile ..........................................................................17 12.3 Drain Voltage Start-up Profile ............................................................................17 12.4 Output Ripple Measurements ............................................................................18 12.4.1 Ripple Measurement Technique.................................................................18 12.4.2 Measurement Results.................................................................................19 13 Conducted EMI .....................................................................................................20 14 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-41 5V and 22V LCD TV Standby PS November 18, 2004 1 Introduction This document is an engineering report describing a prototype power supply for an LCD TV Standby application. The design uses TNY263P. E-shieldTM technology is adopted to achieve good EMI performance without using X cap, Y cap and common mode choke. This document contains the power supply specifications, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. The design passes EMI with a very small EMI filter, made possible by TNY263 built-in frequency jitter. In the actual system, the standby supply can be connected to the EMI filter of the main power supply. 2 Photograph Figure 1 - Circuit Board Photograph Note: In this prototype, R9 is placed on the topside of the PCB and soldered in series with R6 Page 3 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 3 Power Supply Specification Description Input Voltage Frequency Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Total Output Power Continuous Output Power No Load Input Power Efficiency Environmental Conducted EMI Safety Ambient Temperature TAMB Meets CISPR22 / EN55022B Designed to meet IEC950, UL1950 Class II Symbol VIN fLINE VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 Min 80 47 4.85 Typ Max 288 64 5.15 300 Units VAC Hz V mV mA V mV mA Comment 2 Wire - no P.E. 50/60 5 3% 20 MHz Bandwidth 22 100 Primary side 20 MHz Bandwidth POUT PNoLoad 3.7 25 76 W mW % @ 240 Vac Input Measured at 3.7W load 40 o C Page 4 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 4 Schematic Figure 2 - Schematic Note: R9 is placed on the topside of the PCB and soldered in series with R6. L1, L2, R13, R14, C1 and C2 form an EMI filter. C1 and C2 form the bulk capacitance. In the actual system, the standby supply can be connected to the EMI filter and bulk capacitor of the main power supply; it may be possible to simplify the input circuit to take advantage of the main power supply filter and bulk capacitor. If the main PSU bulk capacitor is far from the standby supply, other configurations of simplified filtering may be possible for optimal noise and cost performance. Page 5 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 5 Circuit Description This circuit is configured as an AC to DC two-output Flyback power supply using the highly integrated TNY263P power IC. The circuit is designed for 80 Vac to 288 Vac input with 5V and 22V outputs. 5.1 Input Rectification AC input power is rectified by a full bridge, consisting of D1 through D4. The rectified DC is then filtered by the bulk storage capacitors C1 and C2. Inductor L1 and L2, C1 and C2 form a pi () filter, which attenuates conducted differential-mode EMI noise. R13 and R14 damp the oscillation caused by L1 and L2. 5.2 Auxiliary Bias Supply and the 22V Primary Output The auxiliary bias supply circuit and the 22V primary output are made up of the primaryside transformer bias windings, diode D8, D9, capacitor C7, C10, resistor R12 and Zener diode VR1. R12 was set for just enough current to disable the internal current source. As a result, the standby power consumption is minimized. VR1 improves 22V regulation when 22V is not loaded and 5V output is fully loaded. The 22V winding and the bias winding are wound next to the 5V winding for good cross-regulation. 5.3 Primary DRAIN Voltage Clamp Circuit The DRAIN voltage clamp circuit is comprised of C3, R2 and diode D5. D5 and C3 clamp the amplitude of the voltage spike that the transformer leakage inductance generates at switch turn-off, to keep it beneath the device's maximum DRAIN to SOURCE voltage rating (700 V). R2 damps the high frequency ringing caused by leakage inductance, which improves the conducted EMI performance of the circuit. 5.4 Output Rectification and Filtering Output rectification and filtering are accomplished by Schottky diode D6, capacitors C4, C6 and L3. 5.5 Output Voltage Sensing and Feedback LMV431 U3, resistors R4, R5, R6, R7, R8, R9, C9 and Opto-coupler U2 sense the output voltage and current, and feedback their information to the TNY263P controller. Page 6 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 6 PCB Layout Figure 3 - Printed Circuit Layout. Note: R9 is placed on the topside of the PCB and soldered in series with R6. R1 and R3 are replaced by jumpers. Page 7 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 7 Bill Of Materials Item Qua. Part Reference 1 2 3 2 C1 C2 1 C3 1 C4 10 uF 470 pF 220 uF 10 uF, 450 V, Electrolytic 470 pF, 1 kV, Disc Ceramic Customer Provided NCD471K1KVY5F N/A NIC Components Corp United Chemi-Con Value Description Mfg Part Number Mfg 220 uF, 10 V, Electrolytic, Very Low ESR, 130 mOhm, (6.3 x KZE10VB221MF11LL 11) 4 5 6 7 1 C6 2 C7 C10 2 C8 C9 47 uF 22 uF 100 nF 47 uF, 16 V, Electrolytic, Low ESR, 500 mOhm, (5 x 11.5) 22 uF, 50 V, Electrolytic, Low ESR, 900 mOhm, (5 x 11.5) 100 nF, 50 V, Ceramic, X7R 1000 V, 1 A, Rectifier, DO-41 LXZ16VB47RME11LL LXZ50VB22RME11LL ECU-S1H104KBB 1N4007 United Chemi-Con United Chemi-Con Panasonic Vishay 4 D1 D2 D3 1N4007 D4 8 9 10 11 12 1 D5 1 D6 1 D8 1 D9 6 J1 J2 J3 J4 J5 J6 1N4007GP 11DQ06 BAV20 UF4003 Terminal 1000 V, 1 A, Rectifier, Glass Passivated, 2 us, DO-41 60 V, 1.1 A, Schottky, DO-41 200 V, 200 mA, Fast Switching, 50 ns, DO-35 200 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 PCB Terminal Hole 1N4007GP 11DQ06 BAV20 UF4003 N/A Vishay International Rectifier Vishay Vishay N/A 13 14 2 L1 L2 1 L3 1 mH FB 1 mH, 0.15 A, Ferrite Core 3.5 mm x 7.6 mm, 75 Ohms at 25 MHz, 22 AWG hole, Ferrite Bead SBCP-47HY102B 2743004112 Tokin Fair-Rite 15 16 17 18 19 20 1 R2 1 R4 1 R5 1 R6 1 R7 3 R8 R13 R14 300 k 160 10 k 75 k 24.9 k 4.7 k 300 k, 5%, 1/2 W, Carbon Film 160 R, 5%, 1/8 W, Carbon Film 10 k, 5%, 1/4 W, Carbon Film 75 k, 1%, 1/4 W, Metal Film 24.9 k, 1%, 1/4 W, Metal Film 4.7 k, 5%, 1/8 W, Carbon Film CFR-50JB-300K CFR-12JB-160R CFR-25JB-10K MFR-25FBF-75K0 MFR-25FBF-24K9 CFR-12JB-4K7 Yageo Yageo Yageo Yageo Yageo Yageo 21 22 23 24 25 26 27 28 1 R9 1 R12 1 RF1 1 T2 1 U1 1 U2 1 U3 1 VR1 806 4.22 k 8.2 TRANSFORMER TNY263P PC817D LMV431_A 1N5252B 806 R, 1%, 1/4 W, Metal Film 4.22 k, 1%, 1/4 W, Metal Film 8.2 R, 2.5 W, Fusible/Flame Proof Wire Wound Custom TinySwitch-II, TNY263P, DIP-8B Opto coupler, 35 V, CTR 300-600%, 4-DIP 1.24V Shunt Reg IC 24 V, 5%, 500 mW, DO-35 MFR-25FBF-806R MFR-25FBF-4K22 CRF253-4 5T 8R2 Yageo Yageo Vitrohm TNY263P ISP817D, PC817X4 LMV431ACZ 1N5252B Power Integrations Isocom, Sharp National Semiconductor Microsemi Note: L1, L2, R13, R14, C1 and C2 form an EMI filter. C1 and C2 form the bulk capacitance. In the actual system, the standby supply can be connected to the EMI filter and bulk cap of the main power supply. If the main PSU bulk cap is far from the standby supply, a small HF bypass cap, 0.01uF/400V, should be used in the position of C2. Page 8 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 8 Transformer Specification 8.1 Electrical Diagram NC WD#1 26T #36 x 2 Cancellation 1 WD#2 Primary 10 8T # 30 x 2 TIW 8 Secondary WD#4 5V 1 106T #36 2 3 20T #33 NC 17T #33 x 2 1 WD#3 Bias & Primary 22V O/P WD#5 Cancellation 4 14T #33 5 Figure 4 -Transformer Electrical Diagram 8.2 Electrical Specifications 1 second, 60 Hz, from Pins 1 - 5 to Pins 8 -10 Pins 1-2, all other windings open, measured at 132 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with Pins 8-10 shorted, measured at 132 kHz, 0.4 VRMS 3000 VAC 2.36 mH, 10/+10% 500 kHz (Min.) 50 H (Max.) Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 8.3 [1] [2] [3] [4] [5] [6] Materials Item Core: PC40EE16-Z, TDK or equivalent Gapped for AL of 209 nH/T2 Bobbin: Horizontal 10 pin Magnet Wire: #36 AWG Magnet Wire: #33 AWG Triple Insulated Wire: #30 AWG Tape: 3M 1298 Polyester Film, 2.0 mils thick, 8.2 mm wide Description Page 9 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 8.4 5V and 22V LCD TV Standby PS November 18, 2004 Transformer Build Diagram WD#5 1 WD#4 5V Secondary O/P 5 4 3 1 Cancellation 10 8 WD#3 Bias & 22V Primary O/P 2 1 WD#2 Primary WD#1 Cancellation Figure 5 - Transformer Build Diagram. 8.5 Transformer Construction Bobbin Preparation WD#1 Cancellation Insulation WD#2 Primary Insulation Primary pin side of the bobbin orients to the left hand side. Start on Pin 1, wind 26 turns bifilar of item [3] from left to right. Wind with tight tension across entire bobbin evenly. Cut the end lead after finishing the 26th turn. 2 Layers of tape [6] for insulation Start on pin 2, wind 53 turns of item [3] from left to right. After finishing the first layer, apply 1 layer of tape [6]. Bring the wire back to the left side and continue to wind the wire from left to right with another 53 turns. After finishing the 53rd turn, bring the wire back and finish it on Pin 1. 1 Layer of tape [6] for insulation. The first winding section: start on Pin 3, wind 20 turns of item [4]. Wind from left to right with tight tension. After finishing the 20th turn, bring the wire back and finish it on pin 4. The second winding section: start from Pin 4, rout the wire to the position at where the previous winding finished, wind 14 runs of item [4] from left to right with tight tension. After finishing the 14th turn, bring the wire back and finish it on Pin 5. 2 Layers of tape [6] for insulation. Start at pin 3 temporally, wind 8 turns bifilar of item [5] from left to right, wind uniformly. Tie the finishing lead to pin 8. Bring the starting lead to right side and finish it on Pin 10. 2 Layers of tape [6] for insulation. Start at pin 1, wind bifilar turns of item [4] from left to right, wind uniformly. Cut the finishing lead. 3Layers of tape [6] for insulation. Grind the core to get 2.36mH. Secure the core with tape. Varnish the transformer. WD #3 Bias and Primary O/P 22V Insulation WD #4 Secondary Insulation WD #5 Cancellation Insulation Finish Page 10 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 9 Transformer Spreadsheets ACDC_TNY-II_040104; Rev.1.1; Copyright Power Integrations Inc. 2004 INPUT OUTPUT UNIT ACDC_TNYII_040104_Rev1-1.xls; TinySwitch-II Continuous/Discontinuous Flyback Transformer Design Spreadsheet ENTER APPLICATION VARIABLES VACMIN VACMAX fL VO PO n Z tC CIN 20 80 288 50 5 4 0.7 0.5 s uFarads Input Filter Capacitor Volts Volts Hertz Volts Watts Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage Output Power Efficiency Estimate Loss Allocation Factor 3 mSecond Bridge Rectifier Conduction Time Estimate ENTER TinySwitch-II VARIABLES TinySwitch-II TNY26 3 Universal 115 Doubled/230V Chosen Device Power Out 4.7W 0.195 Amps 0.225 Amps 132000 Hertz 120000 Hertz 144000 Hertz 74 12 0.56 0.68 Volts 12 Volts Volts 7.5W TinySwitch-II Minimum Current Limit TinySwitch-II Maximum Current Limit TinySwitch-II Switching Frequency TinySwitch-II Minimum Switching Frequency (inc. jitter) TinySwitch-II Maximum Switching Frequency (inc. jitter) Reflected Output Voltage TinySwitch-II on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (0.6 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type Core Bobbin EE16 P/N: P/N: 0.192 cm^2 3.5 cm 1140 nH/T^2 8.5 mm mm 2 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 AE LE AL BW M L NS DC INPUT VOLTAGE PARAMETERS VMIN VMAX 94 Volts 407 Volts Minimum DC Input Voltage Maximum DC Input Voltage CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG 0.47 0.06 Amps Maximum Duty Cycle Average Primary Current Page 11 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 IP IR IRMS 5V and 22V LCD TV Standby PS 0.20 Amps 0.13 Amps 0.09 Amps Minimum Peak Primary Current Primary Ripple Current Primary RMS Current November 18, 2004 TRANSFORMER PRIMARY DESIGN PARAMETERS LP NP ALG BM BAC ur LG BWE OD INS DIA AWG CM CMA 2364 uHenries 106 209 nH/T^2 2602 Gauss 772 Gauss 1654 0.09 mm 17 mm 0.16 mm 0.04 mm 0.12 mm 37 AWG 20 Cmils p Primary Inductance Primary Winding Number of Turns Gapped Core Effective Inductance Maximum Flux Density, (BP<3100) AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core !!! INCREASE GAP>>0.1 (increase NS, increase VOR, use a bigger Core 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) Bare conductor effective area in circular mils 218 Cmils/Am Primary Winding Current Capacity (200 < CMA < 500) TRANSFORMER SECONDARY DESIGN PARAMETERS Lumped parameters ISP ISRMS IO IRIPPLE CMS AWGS DIAS ODS INSS 2.60 Amps 1.29 Amps 0.80 Amps 1.01 Amps 258 Cmils 25 AWG 0.46 mm 1.06 mm 0.30 mm Peak Secondary Current Secondary RMS Current Power Supply Output Current Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire Maximum Secondary Insulation Wall Thickness VOLTAGE STRESS PARAMETERS VDRAIN PIVS 583 Volts 36 Volts Maximum Drain Voltage Estimate (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS) 1st output VO1 IO1 PO1 VD1 NS1 ISRMS1 IRIPPLE1 PIVS1 5 0.3 5 Volts 0.300 Amps 1.50 Watts 0.56 Volts 8.00 0.484 Amps 0.38 Amps 36 Volts Output Voltage (if unused, defaults to single output design) Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage CMS1 AWGS1 DIAS1 97 Cmils 30 AWG 0.26 mm Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Page 12 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 ODS1 5V and 22V LCD TV Standby PS 1.06 mm November 18, 2004 Maximum Outside Diameter for Triple Insulated Wire Bias output VO2 IO2 PO2 VD2 NS2 ISRMS2 IRIPPLE2 PIVS2 0.7 13.96 0.161 Amps 0.13 Amps 62 Volts 9 0.1 Volts Amps 0.90 Watts Volts Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage CMS2 AWGS2 DIAS2 ODS2 32 Cmils 34 AWG 0.16 mm 0.61 mm Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Pirmary output VO3 IO3 PO3 VD3 NS3 ISRMS3 IRIPPLE3 PIVS3 1.4 33.67 0.161 Amps 0.13 Amps 151 Volts 22 0.1 Volts Amps 2.20 Watts Volts Output Voltage Output DC Current Output Power Output Diode Forward Voltage Drop Output Winding Number of Turns Output Winding RMS Current Output Capacitor RMS Ripple Current Output Rectifier Maximum Peak Inverse Voltage CMS3 AWGS3 DIAS3 ODS3 32 Cmils 34 AWG 0.16 mm 0.25 mm Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Triple Insulated Wire Total power 4.6 Watts !!! Total power does not match entered power in cell B7 Page 13 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 10 Performance Data All measurements performed at room temperature, 60 Hz input frequency. 10.1 Line and Load Regulation Input (VAC) 5V Output Voltage (V) Current (mA) 22V Output Voltage (V) Current (mA) Note 100 100 0 100 0 100 100 0 100 0 5.01 5.01 80 5.01 5.01 5.01 5.01 5.01 5.01 5.01 5.01 300 9 300 0 0 300 1 300 0 0 21.65 19.98 23.64 18.96 21.41 21.62 19.96 23.58 19.55 21.43 5V minimum load for 22V O/P 10% Regulation 288 5V minimum load for 22V O/P 10% Regulation 10.2 Efficiency 90 Efficiency (%) 80 70 60 50 70 95 120 145 170 195 220 245 270 295 320 Input Voltage (V) Figure 6 - Efficiency vs. Input Voltage at full load, Room Temperature, 60 Hz. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 22 DER-41 5V and 22V LCD TV Standby PS November 18, 2004 10.3 No-Load and Minimum Load Input Power 25 20 Input Power (mW) 15 10 5 0 70 95 120 145 170 195 220 245 270 295 320 Input Voltage (Vac) No Load Figure 7 - No Load Input Power vs. Input Line Voltage Conditions of the measurement: The power supply has to be turned on for at least 30 minutes for thermal stabilization before the No-Load power consumption is taken. Or, turn the power supply on at full load for 5 minutes, then measure the No-Load input power. 10.4 Overload Protection Requirement: At 100VAC, when 22V is set at 100mA, the PS should go to auto restart if 5V is loaded up to 1.2A Test Result: Comment: Under the specified condition, the PS goes to auto restart when the 5V is loaded up to 0.66A PASS Page 15 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 11 Thermal Performance Test Condition: The power supply is set on the bench, open air, full load. The test is done at room temperature. Temperature (C) Item Ambient (Deg.C) TNY263P (U1) 45 80 VAC 25 43 288 VAC Page 16 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 12 Waveforms 12.1 Drain Voltage Normal Operation Figure 8 - 80 VAC, Full Load. VDRAIN, 100 V, 10 s / div Figure 9 - 288 VAC, Full Load. VDRAIN, 100 V, 10 s / div 12.2 Output Voltage Start-up Profile 13V 13V 5V 5V Figure 10 - Start-up Profile, 80 VAC 2V/div for 5V, 10V/div for 22V, 20 ms / div. Figure 11 - Start-up Profile, 288 VAC 2V/div for 5V, 10V/div for 22V, 20 ms / div. 12.3 Drain Voltage Start-up Profile Figure 12 - 80 VAC Input and Maximum Load. VDRAIN, 100 V & 2 ms / div. Figure 13 - 288 VAC Input and Maximum Load. VDRAIN, 100 V & 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 17 of 22 DER-41 5V and 22V LCD TV Standby PS November 18, 2004 12.4 Output Ripple Measurements 12.4.1 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 14 and Figure 15. 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) 1.0 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 14 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed) Figure 15 - 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 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 12.4.2 Measurement Results Figure 16 - 80 VAC, Full Load. 5V 500 us, 100 mV / div Figure 17 - 288 VAC, Full Load. 5V 500 us, 100 mV / div Figure 18 - 80 VAC, Full Load. 22V 500 us, 200 mV / div Figure 19 - 288 VAC, Full Load. 22V 500 us, 200 mV / div Page 19 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 13 Conducted EMI L1, L2, R13, R14, C1 and C2 form an EMI filter. C1 and C2 form the bulk capacitance. In the actual system, the standby supply can be connected to the EMI filter and bulk cap of the main power supply. If the main PSU bulk cap is far from the standby supply, a small HF bypass cap, 0.01uF/400V, should be used in the position of C2. EMI was tested at room temperature, 230 VAC input (worst case), full load. Figure 20 - Line, secondary connected with Ground of the LISN Figure 21 - Line, secondary floating Figure 22 - Neutral, secondary connected with Ground of the LISN Figure 23 - Neutral, secondary floating Page 20 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 2004 14 Revision History Date November 19, 2004 Author DZ Revision 1.0 Description & changes Initial Release Reviewed VC / AM Page 21 of 22 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-41 5V and 22V LCD TV Standby PS November 18, 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 CHINA (SHENZHEN) Power Integrations International Holdings, Inc. Rm# 1705, Bao Hua Bldg. 1016 Hua Qiang Bei Lu, Shenzhen, Guangdong, 518031, China Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com GERMANY Power Integrations, GmbH Rueckertstrasse 3, D-80336, Munich, Germany Phone: +49-895-527-3910 Fax: +49-895-527-3920 e-mail: eurosales@powerint.com ITALY Power Integrations s.r.l. Via Vittorio Veneto 12, Bresso, Milano, 20091, Italy Phone: +39-028-928-6001 Fax: +39-028-928-6009 e-mail: eurosales@powerint.com JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama, 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com KOREA Power Integrations International Holdings, Inc. 8th Floor, DongSung Bldg. 17-8 Yoido-dong, Youngdeungpo-gu, Seoul, 150-874, Korea Phone: +82-2-782-2840 Fax: +82-2-782-4427 e-mail: koreasales@powerint.com 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 CHINA (SHANGHAI) Power Integrations International Holdings, Inc. Rm 807, Pacheer, Commercial Centre, 555 Nanjing West Road, Shanghai, 200041, China Phone: +86-21-6215-5548 Fax: +86-21-6215-2468 e-mail: chinasales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 INDIA (TECHNICAL SUPPORT) Innovatech 261/A, Ground Floor 7th Main, 17th Cross, Sadashivanagar Bangalore, India, 560080 Phone: +91-80-5113-8020 Fax: +91-80-5113-8023 e-mail: indiasales@powerint.com 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 Page 22 of 22 |
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