TABLE 1: ELECTRICAL SPECIFICATIONS AT 25 OC FIGURE 1: SCHEMATIC DIAGRAM SWITCHING TRANSFORMER DESIGNED FOR USE WITH POWER INTEGRATIONS PWR-TOP204YAI. REFER TO APPLICATION CIRCUIT OF FIGURE 3. PARAMETER MIN. SPEC LIMITS TYP. PRIMARY INDUCTANCE (3-1) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ 729 810 MAX. UNITS 891 µHY WHITE DOT ON BOBBIN DENOTES PIN #1 1 PRIMARY 2 10,9 SECONDARY 4 TURN RATIO'S: SEC (11,12-7,8) : PRIMARY (3-1) BIAS (6-5) : PRIMARY (3-1) PRI LEAKAGE IND. (SEC SHORTED) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ HIPOT: PRIMARY TO SECONDARY BIAS TO SECONDARY APP CIRCUIT PARAMETERS: (1) AC LINE VOLTAGE 47/400 Hz OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS OUTPUT CURRENT PEAK LINE REGULATION (85 TO 265Vac) LOAD REGULATION 10-100% RIPPLE --------------- 1:8.250 1:8.250 --------------- + 3% + 3% -------- 15.0 20.0 µHY 3000 3000 --------------- --------------- Vrms Vrms 85 -------15.0 --------------0.20 0.20 50.0 265 Vac Vdc Amps Amps +% +% +mV 0.0 ----------------------------- 3.33 3.5 ---------------------- (1) REFER TO APPLICATION CIRCUIT OF FIGURE 3. 7,6 BIAS 5 SECONDARY PINS #10 & 9, #7 & 6 MUST BE RESPECTIVELY CONNECTED TOGETHER FOR PROPER OPERATION. I.E. CONNECTED AS ONE PARALLEL WINDING. NOTE1: REINFORCED INSULATION SYSTEM, UL1950, IEC950, CSA-950: A) ALL MATERIALS MEET "UL", "CSA" & "IEC" REQUIREMENTS B) TRIPLE BASIC INSULATED SECONDARY. C) DESIGNED TO MEET >6.2mm CREEPAGE REQUIREMENTS. D) VARNISH FINISHED ASSEMBLY. E) UL1950 & CSA-950 CERTIFIED: FILE #E162344. F) UL CLASS (B) 130 INSULATION SYSTEM PM130-H1A (UL FILE #E177139) OR ANY UL AUTHORIZED CLASS (B) INSULATION SYSTEM. FIGURE 2: PHYSICAL DIMENSIONS mm (INCHES) 10 9 8 7 6 P TSD-812 M YYWW PIN #1 I.D. 1 2 3 4 5 29.3 (1.154) MAX 23.5 (.925) MAX CORE TAPED UL INSULATION SYMBOL AND MANUFACTURER IDENTIFICATION HERE 34.5 (1.358) MAX 1 PIN #1 I.D. 5 4.5 (.177) 5.0 (.197) 1 2 3 4 3.0 (.118) 0.8 DIA (.032) 5 17.5 (.689) 10 EER28L, 10-PIN VERTICAL BOBBIN 9 8 7 6 REV. 01/11/96 05/17/99 DESCRIPTION OF CHANGES ORIGINAL RELEASE (POL-15033 USING EER28L CORE/BOBBIN SET) UPDATED TO UL CLASS (B) 130 INSULATION SYSTEM BY TO MD 25.5 (1.004) P Premier M Magnetics Inc. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSIONAL TOLERANCES ARE: DECIMALS ANGLES .X + .25 +0 O 30' .XX + .15 DO NOT SCALE DRAWING TRANSFORMER CONTROL DRAWING PREMIER P/N: TSD-812 REVISION: 05/17/99 DRAWN BY: TOM O'NEIL REF: PWR-TOP204YAI SCALE: NONE SHEET: 1 OF 4 APPLICATION NOTES Premier Magnetic's TSD-812 Switch Mode Transformer was designed for use with Power Integrations, Inc. PWRTOP204YAI three terminal off-line PWM switching regulator in the Flyback Buck-Boost circuit configuration. This conversion topology can provide isolated multiple outputs with efficiencies up to 90%. Premier'S TSD-812 transformer has been optimized to provide maximum power throughput. A lower height version of this same part is Premier part number POL-15033. The PWR-TOPXXX series from Power Integrations, Inc. are self contained 100KHz three terminal voltage controlled PWM switching regulators. This series contains all necessary functions for an off-line switched mode control DC power source. These switching regulators provide a very simple solution to off-line designs. The inductors and transformer used with the PWR-TOPXXX are critical to the performance of the circuit. They define the overall efficiency, output power and overall physical size. Below is a universal input high precision 50 watt application circuit utilizing Power Integrations PWR-TOP204 switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. A properly sized heat sink for the PWR-TOP204 is required for efficient and reliable operation. The use of the VTK-01002 (Sendust type) output inductor will provide maximum efficiency -vs- the lower cost VTP-01002 (-52 powdered iron). Soft start capacitor Css is optional and application dependent. FIGURE 3: TYPICAL APPLICATION CIRCUIT F1 3.1A 250v BR1 KBP04M 400V, 1.5A EMI FILTER LINE 1 L1 PMCE-0330 33mHY ~ 2 + HOT RAIL +115 to 375Vdc C1, 330.0 uF, 400V Nichicon # LLQ2G331MHSB, 85C Diameter=30mm (1.181) Length=30mm (1.181) C1 330 uF 400V + 85-265Vac 50/60Hz C6 0.1uF 4 NEUT 3 ~ - C6 = 0.1uF 250Vac X2-Saftey Cap T1 TSD-812 CLAMP NETWORK 1 VR1 1.5KE200A D3 MBR10100 10,9 2 C2 + 3300uF 35V D2 1N4148 4 4 NEC2501-H C L2 VTP-01002 8uH @ 4.0A PROPERLY SIZED HEAT SINK PRI D1 MUR160 U3 C4 0.1uF PROPERLY SIZED HEAT SINK SEC SOURCE C5 47uF R4 10.0K 1% C3 + 120uF 25V R2 330 1W R2 510 R1 6.2 SOFT START KELVIN CONNECT CONTROL C +15Vdc @ 3.33A RTN 5 E R3 49.9K 1% 7,6 3 + DRAIN 1/2 OF U3 1 1/2 OF U3 A 2 BIAS U1 POWER INT. TOP204Y/TOP226Y PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0330 33mHy EMI/RFI CMC T1 = TSD-812 MAIN SWITCHING TRANSFORMER L2 = VTP-01002 [email protected]([email protected]) INDUCTOR C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF Css + 4.7uF C8 2.2nF 1 U2 C TL431 R A C9 0.1uF 8 6 HIGH VOLTAGE RETURN P Premier M Magnetics Inc. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSIONAL TOLERANCES ARE: DECIMALS ANGLES .X + .25 +0 O 30' .XX + .15 DO NOT SCALE DRAWING TRANSFORMER CONTROL DRAWING PREMIER P/N: TSD-812 REVISION: 05/17/99 DRAWN BY: TOM O'NEIL REF: PWR-TOP204YAI SCALE: NONE SHEET: 2 OF 4