DI-91 Design Idea

®
TinySwitch-III

12 W Universal Input CV Adapter

Application Device Power Output Input Voltage Output Voltage Topology

General Purpose TNY278PN 12 W 85 - 265 VAC 12 V Flyback

Design Highlights The use of an E-shield™ in the transformer, a low-noise drain-

• No-load consumption <50 mW at 265 VAC (R8 fitted)
• Active mode efficiency >75% (CEC 2008, ≥72.4%)
• BP/M pin capacitor value selects MOSFET current limit (ILIMIT–1,
ILIMIT, or ILIMIT+1): for design flexibility
• Output OVP function senses overvoltage on the output through
the primary bias winding
• Accurate (±5%), auto-recovering, hysteretic thermal shutdown
function maintains safe PCB temperatures
• Auto-restart function protects against output short circuits and
open feedback loops
• >3.2 mm package pin creepage: reliable operation in high
humidity and high pollution environments
Operation
This universal input, 12 V, 1 A, flyback converter was designed
around a member of the TinySwitch-III IC family, the TNY278PN.
Because of the many features integrated into the device family, the
supply only requires 31 through-hole components (no SMT), which
enables a simple, single-sided PCB layout to be used.
node clamp (R2, C4 and D5), a single Y capacitor (C5) and the
device’s switching frequency jitter function enable a low-cost pi π
filter (C1, L1 and C2) to attenuate conducted EMI enough to
provide more than 10 dB of margin to EN550022 requirements
(see Figure 4). The clamp circuit Zener (VR1) only conducts briefly
during startup and at worst-case overload, just before the auto-
restart function is activated.
Although TinySwitch-III family members do not need a bias
winding to operate, one was used in this design to take advantage
of the IC’s output OVP detection function. If an open loop fault
causes an overvoltage on the output, VR2 will conduct. When the
current into the BP/M pin exceeds 5.5 mA, an internal latch
triggers and disables MOSFET switching (see Figure 3), until AC
power is removed and reapplied (to reset the latch). Resistor R3
limits the current through VR2, while R3 and R7 attenuate the
portion of the leakage inductance spike that appears in the bias
winding.

C5
2.2 nF
250 VAC
L2
D7 Ferrite Bead
VR1 BYV28-200
P6KE150A T1 3.5 × 7.6 mm +12 V, 1 A
NC 8
C10 C11 J3
D1 D2 R2 1000 μF 100 μF
1N4007 1N4007 100 Ω 1 6 25 V 25 V J4
F1
J1 3.15 A C4 RTN
C1 C2 R1
6.8 μF 22 μF 1 kΩ 10 nF
1 kV 3 R7
4 20 Ω
400 V 400 V
85-265 RV1
VAC 275 VAC
D5
1N4007GP 2 D6
R5* UF4003
J2 3.6 MΩ
D3 D4 5
1N4007 1N4007
L1 VR2
1 mH 1N5255B C6 VR3
28 V 1 μF BZX79-C11
60 V 11 V
R3
47 Ω
*R5 and R8 are optional 1/8 W R6
components 390 Ω
R8* 1/8 W
† 21 kΩ
C7 is configurable to adjust 1% U2
D PC817A
U1 current limit, see circuit EN/UV
description
BP/M
S
S R4
TinySwitch-III C7 † 2 kΩ
U1 100 nF 1/8 W
TNY278PN 50 V

PI-4244-122007

Figure 1. TinySwitch-III 12 W, Universal Input, CV Adapter.

www.powerint.com February 2007

 88

PI-4274-013106
When R8 (optional) is installed, it supplies current to the BP/M pin, 86
which reduces the no-load consumption of the supply. When R5 84
(also optional) is installed, the current it feeds into the EN/UV pin of
82

Efficiency (%)
the IC enables the input undervoltage lockout function (UVLO),
80
and sets the start-up threshold at 65 VAC.
TNY279 (with ILIMIT-1)
78
TNY278 (with std ILIMIT)
The output voltage is determined by the series sum of the voltages 76 TNY277 (with ILIMIT+1)
CEC/ENERGY STAR Minimum
across VR3, R6, and the LED in U2. The values of R4 and R6 can 74 TNY278 (with ILIMIT+1)
be adjusted to fine tune the output voltage of the supply, and a 72
TL431 can be used in place of VR3, for tighter output voltage
70
regulation.
68
Key Design Points 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5
• In the TinySwitch-III family of devices, the MOSFET current limit
Output Current (A)
can be selected from 3 levels by the value of capacitance on
Figure 2. Operating Efficiency vs ILIMIT+, ILIMIT- and Device Size.
the BP/M pin. This gives the designer a number of options,
which are shown in Figure 2. First, a TNY279 could be used,
with the current limit of a TNY278, to obtain higher efficiency.

PI-4288-012506
Second, a TNY277 could be used, with the current limit of a
TNY278, to deliver the same power at a lower efficiency. Lastly,
a TNY278 could be used, with the current limit of a TNY279, to
15

Voltage (V)
extend the power capability of the supply*.
• The UVLO function integrated into U1 only enables MOSFET
switching to occur once the current flowing into the EN/UV pin
exceeds 25 μA. Changing the UVLO threshold voltage requires
changing the value of R5 so that 25 μA flows through it at the
desired threshold voltage. 0
• If output OVP is not required and no-load power consumption
of 150 mW (max, at 265 VAC input) is acceptable, then R7, D6,
C6, R3 and VR2 can be eliminated and the bias winding 0 250 500
removed from T1, for an even lower parts count. Time (ms)
Figure 3. BP/M Pin OVP Function Shuts Down Power Supply.
*Note: This supply was not thermally designed to continuously
deliver the extended power range that could be obtained by
80

PI-4289-012506
operating a TNY278 with its MOSFET current limit set at that of a
TNY279. 70

60
Amplitude (dBμV)

50

40

30

20

-10

-10

-20
0.15 1 10 30

Frequency (MHz)
Figure 4. Conducted EMI Scan (Line): 113 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-91
 DI-140 Design Idea
®
TinySwitch-III

10 W Adapter for Portable Audio Players with Latching Overvoltage and

Over-Temperature Shutdown Protection

Application Device Power Output Input Voltage Output Voltage Topology

MP3/Audio Players TNY278PN 10 W 90 – 265 VAC 5 V ±5% Flyback

Design Highlights Optocoupler feedback using a reference IC was selected to

• Universal input voltage range – single design worldwide provide accurate and tight output regulation. The feedback signal
• Highly energy efficient is fed into the EN/UV pin of U1. IC U1 uses On/Off control to
• Meets CEC/ENERGY STAR 2008 requirements adjust the ratio of enabled to disabled switching cycles to regulate
for active mode efficiency (72.5% vs 70.7% the output. This also optimizes the efficiency of the converter vs.
requirement) load, providing the flat characteristic shown in Figure 2, which is
• Low no-load input power (<200 mW at 230 VAC) ideal for meeting active-mode energy efficiency requirements.
• Excellent EMI margin
• Meets CISPR-22/EN55022B EMI limits with Output overvoltage protection is provided via the latching shut-
>10 dBμV margin down feature of U1. Should the feedback loop open due to
• Conducted scan >30 MHz indicates good radiated component failure, the resulting rise in output voltage is reflected
EMI performance into the bias winding output voltage across C20. Once above the
• Extended protection features sum of the rating of VR1 and the BP/M pin voltage (~12.5 V),
• Latching Overvoltage Protection (OVP) current flows into the BP/M pin. Latching shutdown is triggered
• Latching Over-Temperature protection (OTP) when this current exceeds 6.5 mA. MOSFET switching is disabled
until the BP/M pin capacitor (C4) is discharged below 4.8 V after
Operation removal of input AC.
The flyback power supply shown in Figure 1 employs a
TNY278PN (U1) to generate a 5 V, 2 A output from a A separate case internal ambient temperature shutdown is
90-265 VAC input. Applications include portable audio provided by Q1, C5, RT1, and R6, in addition to the integrated
players, USB chargers, and equipment requiring a 5 V output. 142 °C shutdown of U1. As the temperature, and therefore

F1
250 V
L 0.5 A
D9
KBP06G
T1 L3
EE19 10 MH
C21 10P 5 V, 2 A
90 - 265 1 10
VAC 100 nF
275 VAC D10
C3 SB560
N R3 1 nF
L4 100 k7 1 kV C17 C18 C19
10 mH 1W 330 MF 330 MF 330 MF
10 V 10 V 10 V

D6
1N4007 3 RTN
6
L5 D7 UF4007 C20
Bead 5
1 MF
C1 C2 50 V R11
10 MF 10 MF R13 R8 4.7 k7
400 V 400 V 10 7 560 7
4 R9
VR1 4.7 k7
TinySwitch-III 1N5235B
U1 6.8 V R15
TNY278PN 43 k7
R7
D 47 k7 R6 C12 R12
EN/UV 0.1 MF 4.7 k7
R5 9.1 k7
BP/M 1 k7
R16
S Q1 C6 75 k7
2N5060 100 nF
C4 U3B U2
C22 C16 TL431
0.1 MF PC817A RT1 470 pF
47 pF C5 85 7 250 VAC R10 R14
1 kV 10 nF 90 °C 4.7 k7 43 k7

PI-4639-100608
Figure 1. Schematic of 10 W Adapter Using a TNY278PN.

www.powerint.com October 2008

resistance, of RT1 increases, the voltage at the gate of Q1 rises. 80

PI-4641-040407
Once the gate voltage and current thresholds are exceeded, Q1
conducts, pulling down the BP pin of U1 and disabling switching. 70
The holding current for Q1 is provided via the internal current QP
source of U1 that normally charges C4 during startup. To reset, 60
the AC input must be removed such that current through Q1 falls AV
50
below the specified holding current.

dBMV
Key Design Points 40
• Selecting a fast diode vs an ultra-fast diode for D6 will improve
30
efficiency by recovering leakage inductance energy. If glass
passivated (1N4007GP) is unavailable, 20
a FR107 may be used.
• To prevent an increase in no-load consumption or false OVP 10
triggering, VR1 should be selected to conduct only when the
output voltage is outside the normal regulation range. 0
0.15 1.0 10.0 100.0
• Select a low gate current and low holding current
device for Q1. MHz
• The selectable current limit of U1 allows the current limit and Figure 3. Worst Case Conducted EMI. Region Above 30 MHz Indicates Good
Radiated EMI Performance. (Measured at 230 VAC, Output RTN
device size to be optimized for the thermal environment. For Connected to Artificial Hand Input of LISN)
example, in open frame applications, the TNY277PN part could
be used by changing C4 from 0.1 μF to 10 μF.

Transformer Parameters
77
PI-4640-040407

EE19 NC-2H or equivalent, gapped for ALG of

76 Core Material
200 nH/t²
75 Bobbin EE19, 10 pin, Vertical
74
% Efficiency

Shield: 23T X1, 0.25 mm, tape

73 Primary: 57T, 0.3 mm, 2 layers, tape
115 VAC Winding Details Shield: 23T X1, 0.23 mm
72 230 VAC Secondary: 5T, X2, 0.4 mm T.I.W.
71 Bias: 11T, 0.25 mm

70 Shield (1–NC), Primary (1–3), Shield (4–NC),

Winding Order
Secondary (6–10), Bias (4–5)
69
Primary Inductance 660 μH, ±7%
68
0 20 40 60 80 100 120 Primary Resonant 800 kHz (minimum)
Frequency
% Full Load Leakage
Inductance 30 μH (maximum)
Figure 2. Efficiency vs. Line Voltage.
Table 1. Transformer Parameters. (T.I.W. = 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 ©2007, Power Integrations, Inc.

B
10/08 DI-140