RDK-399 Power Integrations

Reference Design Report for a 12 W Power Title TM Supply Using TinySwitch -4 TNY288PG Specification 85 VAC 265 VAC Input, 12 V, 1 A Output Application TinySwitch-4 Reference Design Author Applications Engineering Department Document RDR-399 Number Date October 9, 2015 Revision 1.2 Summary and Features TM EcoSmart meets all existing and proposed energy efficiency standards including U.S. DOE EISA2007 (Level VI) and European Commission Code of Conduct (Version 5) No-load consumption <140 mW at 265 VAC (no bias winding required) >83% average active-mode efficiency BP/M capacitor value selects power MOSFET current limit for greater design flexibility Output overvoltage protection (OVP) using primary bias winding sensed shutdown feature 2 Tightly toleranced I f parameter (-10%, +12%) reduces system cost Increases MOSFET and magnetics power delivery Reduces overload power, which lowers output diode and capacitor costs Integrated TinySwitch-4 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 >12 dBV margin Meets IEC61000-4-5 Class 3 AC line surge 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.power.com RDR-399 12 V, 1 A, Universal Input Supply 09-Oct-15 Table of Contents 1 Introduction ......................................................................................................... 4 2 Power Supply Specification ................................................................................... 5 3 Schematic ............................................................................................................ 6 4 Circuit Description ................................................................................................ 7 4.1 Input Rectification and Filtering ...................................................................... 7 4.2 TNY288PG Operation ..................................................................................... 7 4.3 Output Rectification and Filtering .................................................................... 8 4.4 Feedback and Output Voltage Regulation ........................................................ 8 4.5 Output Overvoltage Shutdown ........................................................................ 8 4.6 EMI Design Aspects ....................................................................................... 8 4.7 Peak Primary Current Limit Selection .............................................................. 9 4.8 Undervoltage Lockout .................................................................................... 9 5 PCB Layout ........................................................................................................ 10 6 Bill of Materials .................................................................................................. 11 7 Transformer Specification ................................................................................... 12 7.1 Electrical Diagram ........................................................................................ 12 7.2 Electrical Specifications ................................................................................ 12 7.3 Material List ................................................................................................ 12 7.4 Transformer Build Diagram .......................................................................... 13 7.5 Transformer Construction ............................................................................. 13 8 Transformer Design Spreadsheet ........................................................................ 14 9 Performance Data .............................................................................................. 17 9.1 Efficiency .................................................................................................... 17 9.2 Active Mode Measurement Data ................................................................... 18 9.3 No-Load Input Power (R8 Not Installed: No Bias Winding Supplementation) ... 19 9.4 No-Load Input Power (with R8 and IC supplied from bias winding ) ................ 20 9.5 Available Standby Output Power ................................................................... 21 9.6 Regulation ................................................................................................... 22 9.6.1 Load and Line ....................................................................................... 22 10 Thermal Performance ...................................................................................... 23 11 Waveforms ..................................................................................................... 24 11.1 Drain Voltage and Current, Normal Operation ................................................ 24 11.2 Output Voltage Start-Up Profile .................................................................... 25 11.3 Drain Voltage and Current Start-Up Profile .................................................... 25 11.4 Load Transient Response (50% to 100% Load Step) ..................................... 26 11.5 Output Ripple Measurements ........................................................................ 27 11.5.1 Ripple Measurement Technique ............................................................. 27 11.5.2 Measurement Results ............................................................................ 28 11.6 Overvoltage Shutdown ................................................................................. 28 12 Line Surge ...................................................................................................... 29 13 Conducted EMI ............................................................................................... 30 13.1 115 VAC, Full Load ...................................................................................... 30 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 Page 2 of 36 9201