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 efcient
Meets CEC/ENERGY STAR 2008 requirements for active mode
efciency (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 indenitely

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 A) 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 efciency.
Output overvoltage protection is provided via the latching shutdown feature of U1. Should the feedback loop open due to
component failure, the resulting rise in output voltage is reected
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 ows 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.

Operation
The TinySwitch-III multiple output power supply shown in Figure 1
provides 15 W of output power. Typical applications include settop boxes or DVD players where a multiple output yback 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 ltering. 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

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).
C18
470 pF
500 V

C8
1.0 nF
250 VAC
T1
EF25 10

1
R1
47 k
2W

D1, D2
1N4007

F1
2A

L2
1.0 mH

85-300 MOV1
VAC 320 VAC

C2
22 F
450V

R2
220
0.5 W
C7
10 nF
1 kV

C9
470 F
35 V

D8
MUR120
2

9
NC

D9
BYV27-200

D10
1N5822

L4
3.3 H

R15
100

R8
10 k

C12
100 F
35 V

C14
L5 470 F
35
V
3.3 H

C13
470 F
35 V

C15
470 F
35 V

22 V, 0.4 A
C10
100 F
35 V

L3
3.3 H

C11
100 F
35 V

D5
BA159

C3
22 F
450V

L2
3.3 H

D7 MUR120

5 V, 0.45 A
R12
47

VR1
47 V
D

D3, D4
1N4007

EN/UV

RTN

R4
20
5

R6
21 k

3.3 V, 0.75 A

C16
470 F
35 V

4
TinySwitch-III
U1
TNY277PN

8 V, 0.1 A

D6
UF4003
C6
1 F
63 V

U2A

R14
1 k

R5
47

R17
10 k
1%

R18
15 k
1%

C17
100 nF

BP/M
S

C5
100 nF
50 V

C4
10 F

U2B
PC817D

U3
TL431
2%

R16
10 k
1%
PI-4872-020708

Figure 1.

www.powerint.com

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

February 2008

Key Design Points

Components D5, R1 and C7 form an RCD clamp circuit,
absorbing leakage inductance energy during turn off. This
energy is partly recovered when C7 resonates with the
transformer primary leakage inductance and couples into the
secondary side. Resistor R2 damps this resonant ring and
improves EMI.
Diode D5 is a fast diode with reverse recovery tRR of 250 ns.
It may be substituted with a cheaper 1N4007GP (glass
passivated) diode
The selectable current limit of U1 allows the current limit and
device size to be optimized for the thermal environment. For
example, in open frame applications, the TNY276PN part could
be used by changing the value of C5 from 0.1 F to 10 F.
To prevent an increase in no-load consumption or false OVP
triggering, VR1 should be selected to conduct only when the
output voltage is outside the normal regulation range. Resistor
R5 prevents excessive current from owing into the BP/M pin.
To increase coupling between primary and secondary windings,
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
and the DC bus.

83

Efficiency (%)

PI-4877-102507

90
80
70

dBV

60
50
40
30
20
10
0
0.15

1.0

Figure 3.

Transformer Parameters
Core Material

EF25
NC-2H or equivalent,
gapped for ALG of 420 nH/t2

Bobbin

EF25, 10 pin, Horizontal

Winding Details

3 mm margins on both sides of bobbin to meet

safety
Shield: 14T 2, AWG29, tape
Primary-1: 29T 1, AWG29, tape
Bias: 11T 2, AWG29, 3 layers tape
3.3 V: 2T 2, AWG25
5 V: 1T 1, AWG25 (same layer as 3.3 V)
8 V: 1T 1, AWG25 (same layer as 3.3 V),
1 layer tape
22 V: 8T 2, AWG29, 3 layers tape
Shield: 1T Foil 2 mils thick, tape
Primary-2: 29T 1, AWG29, 2 layers tape

Winding Order

Shield (1 - NC), Primary-1 (3-2), Bias (4-5), 3.3 V

(7-6), 5 V (8-7), 8 V (9-8), 22 V (10-9), Shield
(NC-1), Primary-2 (2-1)

75
73
70
85

115

135

180

Line Voltage (VAC)

Figure 2.

Full Load Efciency vs Line Voltage.

230

300

100.0

Worst Case Conducted EMI at 230 VAC With Output Grounded

(CISPR-22 Limit Lines Shown).

80
78

10.0

MHz

PI-4871-102507

85

100

Primary Inductance 1547 H, 10%

Primary Resonant
Frequency

500 kHz (minimum)

Leakage
Inductance

40 H (maximum)

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

TIW = Triple Insulated Wire).

Power Integrations
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Customer Service
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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. POWER INTEGRATIONS
MAKES NO WARRANTY 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.
The products and applications illustrated herein (transformer construction and circuits external to the products) 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 grants
its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.

On the Web
www.powerint.com

The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
2007, Power Integrations, Inc.

C
02/08

DI-163