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Design Example Report
Title Specification Application Author Document Number Date Revision 8.75 W Power Supply using TNY268P Input: 90 - 265VAC Output: 3.5V / 2.5A (4A peak) Adapter Power Integrations Applications Department DER-60 May 27, 2005 1.0
Summary and Features * * * * * * Low cost, low parts count. No Y1 Safety capacitor to pass EN55022B. No load input power < 300mw @ 265VAC. Meet CEC requirement with 3.3V2.5A/ 1.8M 18AWG output cable. Meet LPS < 17.5W with full range input. OTP, OVP latch function.
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.powerint.com
DER-60
Adapter - TNY268
May 27, 2005
Table Of Contents
Introduction................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic................................................................................................................... 5 Circuit Description ...................................................................................................... 6 4.1 Input Rectification and EMI Filtering.................................................................... 6 4.2 TOPSwitch Primary ............................................................................................. 6 4.3 Output Rectification ............................................................................................. 6 4.4 Output Feedback................................................................................................. 6 4.5 OTP, OVP and LPS Protection Circuit ................................................................ 7 5 PCB Layout ................................................................................................................ 8 6 Bill Of Materials .......................................................................................................... 9 7 Transformer Specification......................................................................................... 10 7.1 Electrical Diagram ............................................................................................. 10 7.2 Electrical Specifications..................................................................................... 10 7.3 Materials............................................................................................................ 10 7.4 Transformer Build Diagram ............................................................................... 11 7.5 Transformer Construction.................................................................................. 11 8 Transformer Spreadsheets....................................................................................... 12 9 Performance Data .................................................................................................... 15 9.1 Efficiency........................................................................................................... 15 9.2 No-load Input Power.......................................................................................... 16 9.3 Regulation ......................................................................................................... 17 9.3.1 Load ........................................................................................................... 17 9.3.2 Line ............................................................................................................ 17 10 Waveforms............................................................................................................ 18 10.1 Drain Voltage and Current, Normal Operation .................................................. 18 10.2 Output Voltage Start-up Profile ......................................................................... 19 10.3 Max Output Power (LPS) Testing (Specification Po < 17.5w) ........................... 19 10.4 Load Transient Response ................................................................................. 20 10.5 Output Ripple Measurements............................................................................ 21 10.5.1 Ripple Measurement Technique ................................................................ 21 10.5.2 Measurement Results ................................................................................ 22 11 Conducted EMI ..................................................................................................... 23 12 Revision History.................................................................................................... 24 1 2 3 4
Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
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Page 2 of 25
DER-60
Adapter - TNY268
May 27, 2005
1 Introduction
This document is an engineering report describing an adapter power supply utilizing a TNY268P. This power supply is intended as a general purpose evaluation platform for TNY268P. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data.
(Component side)
(Solder side)
Figure 1 - Populated Circuit Board Photograph
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DER-60
Adapter - TNY268
May 27, 2005
2 Power Supply Specification
Description Input Voltage Frequency No-load Input Power (240 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Continuous Output Power Peak Output Power Efficiency CEC Efficiency (115VAC and 230VAC) Environmental Conducted EMI Safety Symbol VIN fLINE Min 85 47 Typ Max 265 64 0.3 3.7 400 2.5 8.75 14 70 68.6 Units VAC Hz W V mV A W W % % Comment
2 Wire - no P.E.
50/60
VOUT1 VRIPPLE1 IOUT1 POUT POUT_PEAK Avg.
3.3
3.5 300
5% 20 MHz bandwidth
Measured at POUT (8.75 W), 25 oC Avg. Eff. At 25%, 50%, 75% and 100% load
Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II
Ambient Temperature
TAMB
0
40
o
C
Free convection, sea level
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DER-60
Adapter - TNY268
May 27, 2005
3 Schematic
Figure 2 - Schematic
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DER-60
Adapter - TNY268
May 27, 2005
4 Circuit Description
A Flyback converter is used to obtain 3.5V 2.5A output from 90-265 VAC input. The bias winding, which also serves as core cancellation winding to reduce EMI noise, provides current to the BP pin of TNY268P, to reduce the No-Load Input Power consumption by about 0.1 W. 4.1 Input Rectification and EMI Filtering Fuse F1 protects the charger against any fault condition, and input current exceeds 1A. Diodes D1, D2, D3, and D4 form Full-bridge rectifier, and rectify the AC voltage into DC voltage and charge the capacitors C1 and C2. L1, L2, C1, and C2 form - filter and attenuate EMI noise. Here, C1 and C2 act as both storage capacitors and part of EMI filter, which reduces the total cost. 4.2 TOPSwitch Primary
This design uses RCD (C3, D5, R4, and R3) clamping across primary winding to limit the drain voltage below 700V, when the Mosfet inside U1 turns OFF. The capacitor C4 connected to BP (by-pass) pin of U1 stores energy and provide power for the internal circuit of U1 and also to turn ON the U1's Mosfet, during power-up and steady state operation. C11, D11, and R19 form bias supply components, which provide power to the BP pin during steady state operation. This will reduce the No-load input power consumption. R45 limits the current flowing to BP pin, and it is tuned to reduce the Noload input power to minimum. The opto-coupler transistor pulls down enable (EN) pin of U1. TinySwitch-II keeps on switching as long as the pull down current < 250 A. U1 will stop switching if the pull down current exceeds 250 A. 4.3 Output Rectification
When U1 Mosfet is turned ON, current flows through transformer primary and stores energy. When U1 is ON, output diode D20 is OFF. When the U1 Mosfet is OFF, D20 is forward biased, and the stored energy is transferred to the secondary and stores in C22, C23 and C25. The snubber C21 and R20 across secondary winding will improve EMI. 4.4 Output Feedback Resistors R30, R31 divide down the supply output voltage and apply it to the reference pin of error amplifier U22. Shunt regulator U22 drives optocoupler U20 through resistor R28 to provide feedback information to the U1 EN pin. Capacitor C27 drives the optocoupler during supply startup to reduce output voltage overshoot. C26 plays a role in compensating of the power supply feedback loop.
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DER-60
Adapter - TNY268
May 27, 2005
4.5 OTP, OVP and LPS Protection Circuit Q1, Q3, R11 and R21 from a SCR to pull BP pin act as a latch circuit. R8 is a thermal resistor of a NTC type. R8 and R9 from an OTP's trigger circuit of the SCR. The SCR will be triggered when temperature raise to OTP setting point. D21, R27, R44, U23 and R1 form an OVP trigger circuit of the SCR. voltage raise to let D21 conducted, it will trigger the SCR for protection. When output
R33, C36, D24 and R36 form a LPS trigger circuit of the SCR. R33 and C36 set at about 300ms delay time for peak 4A output current testing. (The peak current testing is 4A/200ms/ 1A/us and 0.25A/ 1800ms/ 1A/us, and then the output voltage can't be less than 3V.) If the output load is increased, the bias voltage will be increased too. When the bias voltage increased to LPS setting point, it will let D24 conducted to trigger the SCR for protection.
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DER-60
Adapter - TNY268
May 27, 2005
5 PCB Layout
Figure 3 - Printed Circuit Layout
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DER-60
Adapter - TNY268
May 27, 2005
6 Bill Of Materials
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Quantity 1 1 1 4 1 1 2 1 1 5 1 1 1 1 1 1 1 1 1 1 3 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 2 1 C1 C2 C3 C4,C8,C11,C26 C14 C21 C22,C24 C27 C36 D1,D2,D3,D4,D11 D5 D20 D21 D24 F1 J1 L1 L2 Q1 Q3 R1,R27,R28 R3 R4 R6,R7 R8,R19 R9,R11 R12 R20 R29 R30 R31 R33 R36 R44 T1 U1 U20,U23 U22 Reference Description 10UF/400V 22UF/400V 2200pF/1KV 100n 0.01U/250VAC 2.2nF/100V 1000uF/6.3V 1U/16V 22U/50V 1A / 1000V 1A / 1000V 10A / 40V 3V3/0.5W 30V/0.5W FUSE 250V / 1A AC INLET CHOKE 2mH CHOKE 1mH PNP Transistor NPN Transistor 47R / 0805 200R / 0.5W 68K / 0.5W 1K / 1206 100K / 0805 10K / 0805 2K7 / 0805 5R1/ 0.5W 1K / 0805 4K32,1% 10K,1% 4K7 / 0805 820R / 0805 470R / 0805 Transformer Tiny switch Photo coupler TL431 EI22 TNY268P LTV817B AC INLET DR CORE DR CORE 2SA1015(PNP) 2SC1815(NPN) 1N4007 1N4007GP MBR1040 Part NO.
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DER-60
Adapter - TNY268
May 27, 2005
7 Transformer Specification
7.1 Electrical Diagram
T1 EI22
7 10 N2 0.25mm *1 / 60T / 2L 10 7
33
N4 0.45mm *5 / 3T / 1L Triple Insulated wire
Floating
N3 0.45mm *5 / 3T / 1L
7 55
ting 7
88 N1 0.25mm *2 / 15T / 1L 99
Figure 4 - Transformer Electrical Diagram
7.2
Electrical Specifications
1 second, 60 Hz, from Pins 1-5 to Pins 6-10 Pins 7-10, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 7-10, all other windings open Pin 7-10 with Pin 3-5 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 1.18mH, -/+10% 1MHz (Min.) 30 H (Max.)
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance
7.3
Materials
Description Core: PC40 EI22 Bobbin: EI 22, 10 Pin Magnet Wire: 0.25mm heavy Nyleaze Magnet Wire: 0.45mm heavy Nyleaze Triple Insulated Wire: 0.55mm Tape: 3M 1298 Polyester Film (yellow) 15mm, 0.26m Thick. Tape: 3M 1298 Polyester Film (yellow) 10mm, 0.25mm Thick. Varnish
Item [1] [2] [3] [4] [5] [6] [7] [8]
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DER-60
Adapter - TNY268
May 27, 2005
7.4
Transformer Build Diagram
PIN5
L4 0.55mm * 3 * 1L 3Ts Triple Insulated wire *PIN3
Tape 3L Secondary Tape 3L Primary Tape 1L Primary Tape 1L Primary Tape 1L Primary
NC L3 0.45mm * 5 * 1L 3Ts *PIN7 PIN7
L2 0.25mm * 1 * 2L 60Ts
*PIN10 PIN9
L1 0.25mm * 2 * 1L 15Ts
*PIN8
B0BBIN
Figure 5 - Transformer Build Diagram
7.5
Transformer Construction
Start at Pin 8. Wind 15 turns of item [3] from right to left. Finish at Pin 9. 1Layer of tape [6] for insulation Start at Pin 10. Wind 60 turns / 2Layers of item [3]. Wind 1'st layer from left to right; and add 1 layer of tape [6] for insulation; and then wind 2'nd layer from right to left. Finish at Pin 7. 1Layer of tape [6] for insulation Start at Pin 7. Wind 5-filar 3 turns of item [4] from right to left. Finish at NC. 3Layers of tape [6] for insulation. Start at Pin 3 Wind tri-filar 3 turns of item [5] from left to right. Finish at Pin 5. 3Layers of tape [6 for insulation. Assemble and secure core halves. Put 3 Layers of item [7]. Impregnate uniformly with dip varnish [8]and bake.
Primary Layer Insulation Primary Layer Insulation Primary Layer Insulation Secondary Winding Insulation Final Assembly
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DER-60
Adapter - TNY268
May 27, 2005
8 Transformer Spreadsheets
Power Supply Input
Var VACMIN VACMAX FL TC Z Value 85 265 50 2.51 0.58 Output 1 (main) 3.50 3.00 Output 1 (main) Output 1 (main) Units Volts Volts Hertz mSeconds Description Min Input AC Voltage Max Input AC Voltage Line Frequency Diode Conduction Time Loss Allocation Factor Description Output Voltage Output Current Description PI Device Name Total Output Power Maximum Drain Voltage Drain to Source Voltage TinySwitch-II Switching Frequency Minimum Switching Frequency Maximum Switching Frequency Continuous/Discontinuous Operating Ratio Warning! KRP/KDP is too low Tip: Increase size of TinySwitch-II device, increase efficiency (N), increase reflected output voltage (VOR), increase minimum input voltage (VACMIN) or consider device family with larger power capability. Current Limit Minimum Current Limit Maximum Primary RMS Current Maximum Duty Cycle
Power Supply Outputs
Var VOx IOx Device Variables Var Device PO VDRAIN VDS FSNOM FSMIN FSMAX Value TNY268P 10.5 563 3.18 132000 120000 144000 Value Units Volts Amps
Units Watts Volts Volts Hertz Hertz Hertz
KRPKDP
0.47
ILIMITMIN ILIMITMAX IRMS DMAX
0.51 0.59 0.29 0.50 Output 1 (main)
Amps Amps Amps
Power Supply Components Selection
Var CIN VMIN VMAX VCLO PZ RLS1 Value 33.0 85.0 374.8 200 2.0 2.0 Units uFarads Volts Volts Volts Watts MOhms Description Input Capacitance Minimum DC Input Voltage Maximum DC Input Voltage Clamp Zener Voltage Primary Zener Clamp Loss Line sense resistor
Power Supply Output Parameters
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DER-60
Adapter - TNY268
Output 1 (main) 0.50 22 9.88 5.44 4.54
May 27, 2005
Var VDx PIVSx ISPx ISRMSx IRIPPLEx
Value
Units Volts Volts Amps Amps Amps
Description Output Winding Diode Forward Voltage Drop Output Rectifier Maximum Peak Inverse Voltage Peak Secondary Current Secondary RMS Current Output Capacitor RMS Ripple Current
Transformer Construction Parameters
Var Core/Bobbin Core Manuf. Bobbin Manuf LPmin NP OD Actual Primary Current Density VOR BW M L AE ALG BM BAC LG LL LSEC Value EI22 Generic Generic 1207 60.0 0.23 7 80.00 8.45 0.0 2.00 42.00 335 291 59 0.14 24.1 20 Output 1 (main) 3.0 Output 1 (main) Units Description Core Type Core Manufacturer Bobbin Manufacturer Minimum Primary Inductance Primary Number of Turns Primary Actual Wire Diameter Primary Winding Current Density Reflected Output Voltage Bobbin Winding Width Safety Margin Width Primary Number of Layers Core Cross Sectional Area Gapped Core Effective Inductance Maximum Flux Density AC Flux Density for Core Loss Gap Length Primary Leakage Inductance Secondary Trace Inductance
uHenries mm A/mm^2 Volts mm mm mm^2 nH/T^2 milliTesla milliTesla mm uHenries nHenries
Secondary Parameters
Var NSx Rounded Down NSx Rounded Down Vox Rounded Up NSx Rounded Up Vox Volts Value Units Description Secondary Number of Turns Rounded to Integer Secondary Number of Turns Volts Rounded to Next Integer Secondary Number of Turns Auxiliary Output Voltage for Rounded up to Next Integer Secondary Number of Turns
Volts
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DER-60
Adapter - TNY268
May 27, 2005
Secondary Actual Wire Diameter Range Comment: Secondary wire size is greater than recommended maximum (0.4 mm) Tip: Consider a parallel winding technique (bifilar, trifilar) for >1.5 A outputs, increase size of transformer (larger BW), reduce margin (M).
ODS Actual Range
0.91 1.45
mm
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DER-60
Adapter - TNY268
May 27, 2005
9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency. 9.1 Efficiency 9.1.1 Efficiency vs. input voltage at full load. Efficiency vs input voltage
85 Efficiency (%) 80 75 70 65 90 115 140 165 190 215 240 265
Input Voltage (Vdc)
Figure 6 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
9.1.2 Efficiency vs. output current at 115VAC / 230VAC Efficiency vs Output Current
76 75 74 230VAC 115VAC 76 75 74 73 72 71 70 69 68 67 66 65 25 50 75 100
Efficiency (%)
73 72 71 70 69 68 67 66 65
Avg Eff
115VAC : 72.44% 230VAC : 69.38%
Output Current (%) Figure 7 - Efficiency vs. Input Voltage, Room Temperature, 60 Hz.
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DER-60
Adapter - TNY268
May 27, 2005
9.2 No-load Input Power 9.2.1 Input voltage vs. standby input power Input voltage vs. Standby Input power
300 Input Power (mW) 250 200 150 100 50 0 90 115 140 165 190 215 240 265 AC Input Voltage (VAC)
Figure 8 - Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
9.2.2 Input voltage vs. Input power (Po: 0.5W) Input voltage vs Input power (Po: 0.5W)
1.2 1
Input Power (W)
0.8 0.6 0.4 0.2 0 90 115 140 165 190 215 240 265
AC Input Voltage (VAC)
Figure 9 - Input Line Voltage vs. Input Power (Po: 0.5w), Room Temperature, 60 Hz.
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DER-60 9.3 Regulation
Adapter - TNY268
May 27, 2005
9.3.1 Load Io (A) 0 Vin (AC) 90V 265V 3.594 3.594 3.56 3.56 3.525 3.527 3.49 3.49 3.457 3.457 3.423 3.422 3.38 3.38 0.4 0.8 1.2 1.6 2 2.5
Figure 10 - Load Regulation, Room Temperature
9.3.2 Line Vin (ac) 90 Vo (dc) 3.5V / 0A 3.5V / 2.5A 3.59 3.37 3.59 3.37 3.59 3.37 3.59 3.37 3.59 3.37 3.59 3.37 3.59 3.37 115 140 165 190 215 240
Figure 11 - Line Regulation, Room Temperature, Full Load
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DER-60
Adapter - TNY268
May 27, 2005
10 Waveforms
10.1 Drain Voltage and Current, Normal Operation
Figure 12- 90 VAC, Full Load. Lower: VDRAIN, 100 V/ div, 20 s / div
Figure 13 - 265 VAC, Full Load Lower: VDRAIN, 200 V / div,10 s / div
Figure 14 - 90 VAC, Full Load. Lower: IDRAIN, 200ma/ div, 10 s / div
Figure 15 - 265 VAC, Full Load Lower: IDRAIN, 200ma/ div, 10 s / div
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DER-60
Adapter - TNY268
May 27, 2005
10.2 Output Voltage Start-up Profile
Figure16 - Start-up Profile, 90VAC No Load 1 V/ div, 2 ms / div.
Figure 17 - Start-up Profile, 265 VAC No Load 1V/ div, 2 ms / div.
Figure 18 - Start-up Profile, 90VAC Full Load 1 V/ div, 2 ms / div.
Figure 19 - Start-up Profile, 265 VAC Full Load 1V/ div, 2 ms / div.
10.3 Max Output Power (LPS) Testing (Specification Po < 17.5w)
Vin 90VAC 264VAC
Po < 17.5W 12.5W 13.0W
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Adapter - TNY268
May 27, 2005
10.4 Load Transient Response Peak Load Transient Response, its Test Condition: 4A 200ms with 0.25A 2000ms, slew rate 1A/us
Figure 20 - 90 VAC, 3.5V output; 1V/ Div; 500ms/ Div.
Figure 21 - 90 VAC, 3.5V output; 1V/ Div; 500ms/ Div.
Dynamic Load Response, its Test Condition: Test Condition: 2.5A 50ms with 0.25A 50ms, slew rate 1A/us
Figure 22 - 3.5V output; 1V/ Div; 20ms/ Div
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DER-60
Adapter - TNY268
May 27, 2005
10.5 Output Ripple Measurements 10.5.1 Ripple Measurement Technique For DC output ripple measurements, a modified oscilloscope test probe must be utilized in order to reduce spurious signals due to pickup. Details of the probe modification are provided in Figure 23 and Figure 24. The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe tip. The capacitors include one (1) 0.1 F/50 V ceramic type and one (1) 1.0 F/50 V aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 23 - Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 24 - Oscilloscope Probe with Probe Master 5125BA BNC Adapter. (Modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added)
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DER-60
Adapter - TNY268
May 27, 2005
10.5.2 Measurement Results
Figure 25 - 3.5V Ripple, 90 VAC, Full Load. 50us/ div, 200 mV / div
Figure 26 - 3.5V Ripple, 265 VAC, Full Load. 50us/ div, 200 mV / div
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DER-60
Adapter - TNY268
May 27, 2005
11 Conducted EMI
Figure 27 - EMI Result: 115VAC, 60Hz, 3.5V 2.6A load, and EN55022 B Limits.
Figure 28 - EMI Result: 230VAC, 60Hz, 3.5V 2.6A load, and EN55022 B Limits.
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DER-60
Adapter - TNY268
May 27, 2005
12 Revision History
Date 5-27-05 Author RS Revision 1.0 Description & changes Initial Release Reviewed KM / VC
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DER-60
Adapter - TNY268
May 27, 2005
For the latest updates, visit our Web site: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES 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. PATENT INFORMATION 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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. (c) Copyright 2004, Power Integrations.
Power Integrations Worldwide Sales Support Locations
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ER or EPR template - Rev 3.6 - Single sided
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