EPR-000008

EPR-000008 POWERINT | Alldatasheet

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Power Integrations, Inc. 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408-414-9200 Fax: +1 408-414-9201 www.powerint.com Title Engineering Prototype Report (EPR-000008)

1.2 W, Universal Input, Non-isolated, TNY254 (EP8)

Customer Home Appliance Market Author S.L. Document Number EPR-000008 Date 08-May-2001 Revision 10 Abstract This document presents the specification, schematic & BOM, inductor calculation, test data and wave forms for a low cost, non-isolated, converter for a home appliance application (triac driving).

EPR-000008 – 1.2 W Universal Input Non-Isolated TNY254 23-April-2001 Page 2 of 20Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Table Of Contents

23-April-2001 EPR-000008 – 1.2 W Universal Input Non-Isolated TNY254 Page 3 of 20 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com

1 Introduction

There are three specific requirements for this power supply: 1. To provide power for driving a trial requires that the output power be referenced to the input line (L), with no series impedance, therefore only ½ wave rectification is allowed and the switch must be in the return side of the primary switching circuit. EMI filtering, if necessary, has to be implemented at the system level. 2. The unit has to operate at 85 /g176C ambient. 3. The unit has to withstand 2 kV (configuration “1”, page 4) and 6 kV (configuration ”2”, page 5) input surge voltage as defined by IEC 1000-4-5 (1.2/50 /g109s). The surge protection added to satisfy these requirements reduces the converter efficiency. It would be more beneficial (lower cost, improved efficiency) if the surge protection were implemented at the system (appliance) level.

2 Power Supply Specification

The specification below is for the worst case (6 kV configuration ”2”) Description Symbol Min Typ Max Units Comment Input Input Voltage VAC 85 265 VAC 50/60 Hz Input frequency fLINE 47 63 Hz Output Output Voltage VOUT 10.8 12 13.2 V 12 V+/-10%* Output Ripple Voltage VRIPPLE 80 120 MV of VOUT @ full load Output Current IOUT 0 100 MA ~200 mA short Load Regulation 0-100% load Line Regulation 85-265 VAC, full load Power Output Continuous Output power POUT 0 1.2 W 0-85 /g176C internal ambient** Power supply efficiency /g104 50 % @low line, full load Environmental Temperature TAMB 0 85 C 6” x 6” x 4” enclosure EMI – conducted Designed to meet CISPRR 22B (FCCB) Safety Designed to meet IEC950 Input Surge Voltage Config. ”1” 2 kV IEC1000-4-5 Input Surge Voltage Config. ”2” 6 kV IEC1000-4-5 * +/-5% with 2% Zener. **The unit was placed in a 6” x 6” x 4” enclosure inside the temperature chamber.

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3 Schematic

3.1 Configuration “1” – 2 kV (1.2/50 /g109s) Surge Withstand

23-April-2001 EPR-000008 – 1.2 W Universal Input Non-Isolated TNY254 Page 5 of 20 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 3.2 Configuration “2” – 6 kV (1.2/50 /g109s) Surge Withstand

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4 Circuit Description

The circuit is a fail-safe, non-isolated fly-back topology. Fail-safe means that the output is not subjected to high voltage DC if the swit ch (U1) fails, since the diode D2 blocks the voltage. During the ON time (U1 conducting), L1 is charged up to ILIMIT of the TNY254 (0.25 A type.), from the energy stored in C1. During the OFF time (U1 blocking), the energy stored in L1 is transferred to C3 and the load via D2. The device switching frequency is 44 kHz. The surge protection circuit has to prevent the TinySwitch VDSMAX from exceeding 700 V. The surge protection for configuration ”1” (2 kV) and configuration ”2” (6 kV) is illustrated in the schematics (pages 4, 5). Configuration ”1” relies on the current/energy-limiting resistor R2 to keep the maximum charging voltage of C1 during a +2 kV surge below 700 V. For the -2 kV surge the diodes D1+D3 block the voltage. Configuration ”2” relies on the current/energy-limiting resistor R1 to limit the current in the MOV (RV1) to approximately 50 A peak, such that the RV1 clamping voltage is kept well under 1 kV (~700 V). During the +6 kV surge, R2 limits C1 charging current so that the maximum voltage does not exceed 700 V. During the -6 kV surge, D1 blocks the RV1 clamping voltage from reaching C1. In both configurations, the fusible resistor R2 provides protection for component failure.

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5 Layout

CAUTION! This is a non-isolated power supply with th e low voltage return referenced to the input line (85-265 V AC). Do not touch the unit while it is powered. Power the board using a safety isolation transformer so the high voltage probe return is not referenced to the neutral of the input line. For the drain-to-source voltage waveforms connect the high voltage probe tip to jumper JP1 and the probe ground to test point TP1. For switching current waveforms replace jumper JP1 with a wire loop and use a Tektronix A6302 current probe and AM503 current probe amplifier (with TM501 power module) or equivalent. JP1 TP1PCB cut out for 6 kV only

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6 Bill of Materials

6.1 Configuration ”1”, 2 kV

Item Qty. Ref. Description Manufacturer Part Number 1 1 C1 6.8 /g109F, 400 V, 105 C Rubycon 400BXA6R8M10x16 2 1 C2 0.1 /g109F, 50 V, ceramic Panasonic ECU-S1H104KBB 3 1 C3 220 /g109F 25 V (0.12 /g87) Panasonic 4 2 D1, D3 Glass Passivated Diode Vishay/Lite On 1N4007GP 5 1 D2 600 V, 1 A, 75 ns General Instrument UF4005 6 1 **J1 Header, 3 pos., 0.156 spacing Molex 26-48-1035 7 1 J2 Header, 2 pos., 0.156 spacing Molex 26-48-1025 8 1 *LED1 low current Siemens/HP LG3369/HLMP1790 9 1 L1 1.5 mH, 0.4 ADC, 0.2 AAC, 600 VDC, Chilisin 10 1 R2 180 /g87, flame proof, fusible, 3 W; Vitrohm (Farnell Components.) (08WX7849) 11 1 *R3 8.2 k/g87, ¼ W 12 1 U1 Off-line Switcher Power Integrations TNY254P 13 1 U2 Optocoupler Siemens/NEC SFH615-2/PS2501-1 14 1 VR1 Zener, 12 V /g1775% Diodes Incorporated 1N5242B *Optional **Remove middle pin

6.2 Configuration ”2”, 6 kV

(Add the following items to Configuration "1" and subtract D3) Item Qty. Ref. Description Manufacturer Part Number 15 1 RV1 Varistor, 275 VAC, 14 mm Harris/Littlefuse V275LA20A 16 1 R1 100 /g87, 15 J, 500 VAC Ohmite OX 101

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7 Inductor

7.1 Calculation

The inductor value can be determined using the TNY253-255 flyback transformer spreadsheet with the following considerations: 1) the frequency value (f L) is ½ the line frequency, 25 Hz for 50 Hz, 30 Hz for 60 Hz, to account for half wave rectification. 2) Z factor, the ratio between the secondary losses and the total losses, has to reflect the dominance of the primary losses, as the TinySwitch losses (high R dson) overshadow the output diode losses. Z factor does not reflect the extra power loss due to R1 and R2. The efficiency used in the spreadsheet is only the efficiency of the converter portion of the supply, it does not include the losses in the input resistor. 3) the output diode rating can be calculated from the formula (V R /g179 P IVS/0.8), where PIVS=VMAX+VO-VDS. The inductor can be looked at as a transformer with 1:1 turns ratio, therefore VOR=VO+VD. 4) the output capacitor minimum value is dictated by the output RMS ripple current and the maximum value by the specified maximum output voltage ripple. Select the next higher standard “L” value (for the rated “I”) from a qualified vendor (min. 400 VDC voltage rated inductor) like Chilisin, and the smallest DC resistance.

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7.2 Spreadsheet

ACDC_TNY_Rev1.8_072699 Copyright Power Integrations, Inc. 1999 INPUT OUTPUT UNIT ACDC_TNY_REV1_8_072699.xls: TinySwitch Continuous/Discontinuous Flyback Transformer Design Spreadsheet ENTER APPLICATION VARIABLES Customer VACMIN 77 V Minimum AC Input Voltage VACMAX 265 V Maximum AC Input Voltage fL 25 Hz AC Mains Frequency VO 12 V Output Voltage PO 1.2 W Output Power n 0.65 Efficiency Estimate Z 0.1 Loss Allocation Factor tC 3 mS Bridge Rectifier Conduction Time Estimate CIN 6.8 /g109F Input Filter Capacitor MODE OF OPERATION Continuous ('c') or Discontinuous ('d')? c Continuous Mode Operation or Discontinuous Mode Operation? n Continuous ENTER TinySwitch Parameters Universal 115/230 VAC TinySwitch TNY254 4 W 5 W ILIMITMIN 0.23 A Minimum Current Limit ILIMITMAX 0.28 A Maximum Current Limit fSmin 40000 Hz Minimum Frequency VDS 10 V Voltage Drop Between Drain to Source ENTER Output Diode Parameters Output Diode VR 500 V Diode Maximum Peak Repetitive Reverse Voltage ID 1 A Diode Average Forward Current VD 1 V Diode Forward Voltage Drop k 0.8 Diode Peak to RMS Current Factor (k=0.9 for Schottky, k=0.8 for PN Diode) Design Parameters VMIN 51 V Minimum DC Input Voltage VMAX 375 V Maximum DC Input Voltage IP 0.21 A Peak Primary Current DMAX 0.252 Duty Cycle at Minimum DC Input Voltage KRP 0.62 Ripple to Peak Current Ratio (0.6<KRP<1.0) VOR 13.91 V Reflected Output Voltage VDRAIN 445.63 V Maximum Drain Voltage Estimate PIVS 362 V Output Rectifier Peak Inverse Voltage LP 1552 /g109H Minimum Primary Inductance CURRENT WAVEFORM SHAPE PARAMETERS IAVGmax 0.04 A Maximum Average Primary Current IAVGmin 0.00 A Minimum Average Primary Current IRMS 0.07 A Primary RMS Current IR 0.13 A Primary Ripple Current ISP 0.22 A Maximum Peak Secondary Current ISRMS 0.14 A Secondary RMS current IO 0.10 A Power Supply Output Current IRIPPLE 0.09 A Output Capacitor RMS Ripple Current IOS 0.24 A Estimated Short Circuit Current

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8.0 Performance Data

8.1 Efficiency

INPUT: AC POWER ANALYZER PM1000 (VOLTECH). OUTPUT: ELECTRONIC LOAD PLZ 153 W (KIKUSUI). Figure 8.1.1 - Efficiency vs. Input Voltage. Figure 8.1.2 - Efficiency vs. Output Power. Efficiency vs. Line Voltage 40.00 45.00 50.00 55.00 60.00 65.00 70.00 75.00 80.00 85 105 125 145 165 185 205 225 245 265 V AC , 60 Hz Conf ig. "2", 86 C Am bient Conf ig. "2", 28 C Am bient Conf ig. "1", 28 C Am bient Efficiency vs. Output Power @ 28 C Ambient 40.00 45.00 50.00 55.00 60.00 65.00 70.00 75.00 80.00 I OUT (A) Config. "2", 85 VAC Config. "1", 85 VAC Config. "2", 265 VAC Config. "1", 265 VAC

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8.2 Regulation

Figure 5.2.1 – Line Regulation at Full Load, 28 /g176C Ambient. Figure 5.2.2 – Load Regulation, at 28 /g176C Ambient.

8.3 Temperature

TAMB (/g176C)

265 VAC,

TAMB (/g176C)

85 VAC,

Internal Enclosure 2.3 85.4 TNYSwitch (U 1) 26 100 R2 39 102 Output Diode (D2) 15 90 Input Cap (C1) 17 91 Figure 8.3.1 – Output Voltage at Full Load (0.1 A) Over -70/g176 C to 90/g176 C Ambient. Table 8.1 – Components Temperature at Low and High Ambient Worst case input voltage was selected for the two temperature extremes, 265 V AC (minimum losses) for “Low T” and 85 VAC (maximum losses) for “High T”. The temperature dependence of the output voltage can be reduced by using two, lower voltage Zener diodes in series. The unit shut down at 96 /g176C inside internal enclosure. Load regulation 12.04 12.08 12.12 12.16 I OUT (A) VOUT (V) Config. "2", 85 VAC, 60 Hz Config. "1", 85 VAC, 60 Hz Config. "2", 285 VAC, 60 Hz Config. "1", 265VAC, 60 Hz Line Regulation 12.1 12.2 12.3 12.4 12.5 85 105 125 145 165 185 205 225 245 265 V AC, 60 Hz VOUT (VDC) Config. "2", 88 C Ambient Config. "2", 28 C Ambient Config. "1", 28 C Ambient Output voltage vs Ambient temp. 9.5 10.5 11.5 12.5 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 Temp.(C) Output(V)

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8.4 Waveforms

8.4.1 Turn-on delay/hold-up time

8.4.1.1 2 kV config.”1” 85 V AC Figure 8.4.1.1 - Output Voltage Turn On Delay at Full Load. CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div) Figure 8.4.1.2 - Output Voltage Hold Up Time. CH1: VOUT (2 V/div), CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div) 8.4.1.2 6 kV config.”1” 85 V AC Figure 8.4.1.3 - Output Voltage Turn-on Delay at Full Load. CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div) Figure 8.4.1.4 - Output Voltage Hold-up Time at Full Load. CH1: VOUT (2 V/div), CH2: VOUT (2 V/div), CH4: IIN_MAINS (0.1 A/div) Ch.2 Ch.4, Ch.1 Ch.2 Ch.2 Ch.1, Ch.4, Ch.4, Ch.2, Ch.4,

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8.4.2 Switch Current and Drain-to-Source Voltage

Figure 8.4.2.1 - Full Load at 85 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div) Figure 8.4.2.2 - Short Circuit at 85 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div) Figure 8.4.2.3 - Full Load at 265 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div) Figure 8.4.2.4 - Short Circuit at 265 VAC. CH4: IDRAIN, (100 mA/div), CH2: VDS (100 V/Div) Ch.2 Ch.4 Ch.4 Ch.2 Ch.2 Ch.4 Ch.4 Ch.2

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8.4.3 Output Voltage Ripple

Figure 8.4.3.1 - Switching Ripple at Full Load. CH1: VOUT (50 mV/div), CH4: IOUT (50 mA/div) Figure 8.4.3.2 - Switching Frequency Ripple at Full Load. CH1: VOUT (50 mV/div), CH4: IOUT (50 mA/div) CH1 CH4 CH4 CH1 Vin VOR

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8.5 Transient Response

Figure 8.5.1 - Output Voltage Transient Response at 115 VAC 50-100% Load Change. CH1: VOUT (50 mV/div), CH2: IOUT (50 mA/div) Figure 8.5.2 - Output Voltage Transient Response at 230 VAC 50-100% Load Change. CH1: VOUT (50 mV/div), CH2: IOUT (50 mA/div) CH1 CH4 CH1 CH4

23-April-2001 EPR-000008 – 1.2 W Universal Input Non-Isolated TNY254 Page 17 of 20 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 8.6 Surge Voltage Immunity (2 kV and 6 kV, 1.2/50 /g109s per IEC1000-4-5) Two series of surge tests were performed: surges each at 45 seconds apart; 10 surges with positive (Fig. 8.6.3) and 10 with negative polarity (Fig. 8.6.4), all at high input line and full load. The 45 seconds delay between surges allows the energy rated components (R1, R2 and RV1) to cool down. High input line is the worst case condition as the input capacitor (C1) reaches highest voltage therefore minimizing margin for TinySwitch breakdown voltage. R2 limits the charging current during a +voltage surge such that C1 peak voltage does not exceed the TNY254 breakdown voltage. R1 limits the maximum surge current to approximately 50 A, the value at which the clamping voltage of the varistor is characterized (<700 V). The 6 kV, 1.2/50 /g109s pulse at it can be inferred that the unit will survive 10 k surges of -6 kV (more of +6 kV as C1 can divert ~0.3 J). Reducing the value of R1 would reduce the total number of 6 kV pulses the unit can survive. L N 85-265 VAC, 50/60 Hz 180 /g87, 3 W, fusible 6.8 /g109F 400 V 1N4007 1N4007 J1-1 J1-3 N L 85-265 VAC, 50/60 Hz J1-1 J1-3 R1 100 /g87, surge 6.8 /g109F 400 V +RV1 180 /g87, 3 W, fusible 1N4007

EPR-000008 – 1.2 W Universal Input Non-Isolated TNY254 23-April-2001 Page 18 of 20Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 8.6.3 - RV1 Voltage During +6 kV, 1.2/50 /g109s Surge. Figure 8.6.4 - RV1 Voltage During -6 kV, 1.2/50 /g109s Surge. The pre-trigger voltage is the instantaneous line voltage. The RV1 voltage is post-trigger and is referenced to the ground. Figure 8.6.5 - Varistor Life (Number of Surges) as a Function of the Rectangular Pulse Amplitude and its Duration.

200 V/div 200 V/div

Instantaneous Line Voltage

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Revision History

Date Author Rev Description 5-Aug-1999 S. L. 1 First Draft 30-Aug-1999 S. L 2 Second Draft 7-Sep-1999 S. L 3 Third Draft 16-Oct-1999 S. L 4 Fourth Draft 18-Nov-1999 S. L 5 Fifth Draft 24-Nov-1999 S. L 6 Sixth Draft 23-Feb-2000 S. L 7 Seventh Draft 23-Mar-2000 S. L 8 Release 9-Oct-2000 S. L 9 Pg.6, D1+D2 to D1+D3 23-Apr-2001 S. L 10 Pg.8, 6.2 Config. Items 4 and 10

EPR-000008 – 1.2 W Universal Input Non-Isolated TNY254 23-April-2001 Page 20 of 20Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com For the latest updates, visit our web site: www.powerint.com 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, nor does it convey any license under its patent rights or the rights of others. PI Logo, TOPSwitch and TinySwitch are registered trademarks of Power Integrations, Inc. © Copyright 2001, Power Integrations, Inc. WORLD HEADQUARTERS NORTH AMERICA - WEST Power Integrations, Inc.

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