DI-163 Design Idea

®
TinySwitch-III

Wide Range Set Top Box Power Supply with Latching

Overvoltage (OVP) Shutdown Protection

Application Device Power Output Input Voltage Output Voltage Topology

Set Top Box TNY277PN 15 W 85 – 300 VAC 3.3 V, 5 V, 8 V, 22 V Flyback

Design Highlights
• Multiple output power supply
• Excellent cross regulation
• Two outputs sum-regulated
• Highly energy efficient
• Meets CEC/ENERGY STAR 2008 requirements for active mode
efficiency (77 % vs 68.1% requirement)
• Low no-load power consumption (<150 mW at 230 VAC)
• Meets CISPR-22/EN55022B conducted EMI limits
• Auto-restart withstands shorted output condition indefinitely
Operation
The TinySwitch-III multiple output power supply shown in Figure 1
provides 15 W of output power. Typical applications include set-
top boxes or DVD players where a multiple output flyback supply
is required.
Diodes D1, D2, D3 and D4 and capacitors C2 and C3 rectify and
smooth the AC input. Capacitors C2, C3, C8 and inductor L2
provide differential as well as common-mode EMI filtering. The
controller in U1 receives feedback from the secondary through
optocoupler U2, and based on that feedback, it enables or
disables the switching of its integrated MOSFET to maintain
output regulation. A portion of both the 3.3 V and the 5 V outputs
are fed into the shunt regulator (U3), which controls the current
through the LED in U2. A proportional current is then pulled out of
the EN/UV pin. Switching cycles are skipped once the EN/UV
disable threshold current (115 μA) is exceeded. When the current
out of the EN/UV pin falls below the disable threshold, switching
cycles are re-enabled. The disable threshold is modulated to
reduce group pulsing and ensure evenly spaced current pulses
thereby improving output ripple and overall efficiency.
Output overvoltage protection is provided via the latching shut-
down feature of U1. Should the feedback loop open due to
component failure, the resulting rise in output voltage is reflected
through the bias winding output voltage across C6. Once the
output voltage is above the sum of the rating of VR1 and the
BP/M pin voltage (~53 V), current flows into the BP/M pin.
Latching shutdown is triggered when this current exceeds 7 mA.
MOSFET switching is disabled until the BP/M pin capacitor (C4) is
discharged below 4.8 V after removal of input AC.
Good cross-regulation on 5 V and 3.3 V outputs is achieved by
minimizing secondary leakage by placing the 3.3 V and 5 V
windings on the same layer next to the primary and by sum
regulating (obtaining feedback from both outputs).

C8 C18
1.0 nF 470 pF
250 VAC 500 V

L2
T1 D7 MUR120 3.3 μH
EF25 10 22 V, 0.4 A
1
R2 C9 C10
220 Ω D8 R8
470 μF L3 100 μF 10 kΩ
D1, D2 R1 0.5 W MUR120 35 V 3.3 μH
47 kΩ 2 9 35 V 8 V, 0.1 A
1N4007
2W C7 NC C11 C12
10 nF D9
BYV27-200 100 μF L4 100 μF
1 kV 35 V 3.3 μH 35 V 5 V, 0.45 A
3 8
C13 C14 R12
D5
D10 470 μF L5 470 μF 47 Ω
F1 BA159
1N5822 35 V 3.3 μH 35 V 3.3 V, 0.75 A
L2 7
2A
1.0 mH C15 C16
R15 470 μF
470 μF 100 Ω
6 35 V 35 V
85-300 MOV1 C2 C3
VAC 320 VAC 22 μF 22 μF 4 RTN
450V 450V R4
TinySwitch-III D6
U1 20 Ω UF4003 R14
U2A 1 kΩ
TNY277PN 5 C6 R17 R18
1 μF 10 kΩ 15 kΩ
63 V 1% 1%
VR1
47 V R6 R5
D 21 kΩ 47 Ω C17
EN/UV
100 nF
D3, D4 BP/M
1N4007
S
U2B
C5 C4 PC817D U3 R16
100 nF 10 μF TL431 10 kΩ
50 V 2% 1%

PI-4872-020708

Figure 1. Schematic of a 15 W, Set Top Box Power Supply Using TinySwitch-III.

www.powerint.com February 2008

Key Design Points 100

PI-4877-102507
• Components D5, R1 and C7 form an RCD clamp circuit,
90
absorbing leakage inductance energy during turn off. This
energy is partly recovered when C7 resonates with the 80
transformer primary leakage inductance and couples into the
70
secondary side. Resistor R2 damps this resonant ring and
improves EMI. 60

dBμV
• Diode D5 is a fast diode with reverse recovery tRR of 250 ns.
50
It may be substituted with a cheaper 1N4007GP (glass
passivated) diode 40
• The selectable current limit of U1 allows the current limit and 30
device size to be optimized for the thermal environment. For
example, in open frame applications, the TNY276PN part could 20
be used by changing the value of C5 from 0.1 μF to 10 μF. 10
• To prevent an increase in no-load consumption or false OVP
0
triggering, VR1 should be selected to conduct only when the 0.15 1.0 10.0 100.0
output voltage is outside the normal regulation range. Resistor
MHz
R5 prevents excessive current from flowing into the BP/M pin.
Figure 3. Worst Case Conducted EMI at 230 VAC With Output Grounded
• To increase coupling between primary and secondary windings, (CISPR-22 Limit Lines Shown).
the 3.3 V, 5 V and 8 V windings are all placed on the same layer
• To route currents away from U1 during common-mode surges,
the Y1 capacitor C8 is connected between secondary return Transformer Parameters
and the DC bus. EF25
Core Material NC-2H or equivalent,
gapped for ALG of 420 nH/t2
85
PI-4871-102507

Bobbin EF25, 10 pin, Horizontal

83 3 mm margins on both sides of bobbin to meet
safety
Shield: 14T × 2, AWG29, tape
Efficiency (%)

80
Primary-1: 29T × 1, AWG29, tape
Bias: 11T × 2, AWG29, 3 layers tape
78 3.3 V: 2T × 2, AWG25
Winding Details
5 V: 1T × 1, AWG25 (same layer as 3.3 V)
75 8 V: 1T × 1, AWG25 (same layer as 3.3 V),
1 layer tape
22 V: 8T × 2, AWG29, 3 layers tape
73 Shield: 1T Foil 2 mils thick, tape
Primary-2: 29T × 1, AWG29, 2 layers tape
70 Shield (1 - NC), Primary-1 (3-2), Bias (4-5), 3.3 V
85 115 135 180 230 300 Winding Order (7-6), 5 V (8-7), 8 V (9-8), 22 V (10-9), Shield
(NC-1), Primary-2 (2-1)
Line Voltage (VAC)
Primary Inductance 1547 μH, ±10%
Figure 2. Full Load Efficiency vs Line Voltage.
Primary Resonant 500 kHz (minimum)
Frequency
Leakage
Inductance 40 μH (maximum)

Table 1. Transformer Parameters. (NC = No Connection,

TIW = Triple Insulated Wire).

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02/08 DI-163