TABLE 1: ELECTRICAL SPECIFICATIONS AT 25 O C FIGURE 1: SCHEMATIC DIAGRAM SWITCHING TRANSFORMER DESIGNED FOR USE WITH POWER INTEGRATIONS TOP204Y/TOP226Y & TOP104Y. REFER TO APPLICATION CIRCUITS OF FIGURE 3A, 3B or 3C. PARAMETER MIN. PRIMARY INDUCTANCE (3-1) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ 540 SPEC LIMITS TYP. 600 MAX. UNITS 660 µHY WHITE DOT ON BOBBIN DENOTES PIN #1 1 11,12 PRIMARY 3 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 FIGURE 3A 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 --------------- 1:7.333 1:7.333 --------------- + 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 ---------------------- SECONDARY 5 7,8 BIAS 6 SECONDARY PINS #12 & 11, #8 & 7 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-R1, PM130-H1, PM130-H1A (UL FILE #E177139) OR ANY UL AUTHORIZED CLASS (B) INSULATION SYSTEM. (1) REFER TO APPLICATION CIRCUIT OF FIGURE 3A. FOR 13.8V, 85-132VAC VERSION REFER TO CIRCUIT & TABLE OF FIGURE 3B, TOP104 FIGURE 2: PHYSICAL DIMENSIONS mm (INCHES) 12 11 10 9 8 7 P POL-15033 M YYWW PIN #1 WHITE DOT 1 2 3 4 5 6 31.50 (1.240) MAX CORE TAPED 26.50 (1.043) MAX UL INSULATION SYMBOL AND MANUFACTURER IDENTIFICATION HERE 29.00 (1.142) MAX 1 2 3 5.00 (.197) 4 5 25.00 (.984) 0.8 DIA. (.032) 6 4.0 (.157) MIN UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSIONAL TOLERANCES ARE: DECIMALS ANGLES .X + .25 + 0 O 30' .XX + .15 DO NOT SCALE DRAWING 20.0 (.787) REV. 04/30/96 10/10/98 04/26/99 08/28/03 DESCRIPTION OF CHANGES UPDATED RELEASE UPDATED TO ADD UL 1950 & CE-950 APPROVAL & MARKING UPDATE TO UL CLASS (B) 130 INSULATION SYSTEM ADD 12 V CIRCUIT PAGE #4 TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-15033 REVISION: 08/28/03 DRAWN BY: PETER PHAM REF:TOP204,TOP226 SCALE: NONE SHEET: 1 OF 8 BY TO TO MD PP APPLICATION NOTES FOR 15.0V @ 3.33A Premier Magnetics' POL-15033 Switch Mode Transformer was designed for use with Power Integrations, Inc. TOP204Y or TOP226Y 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%. Premiers' POL-15033 transformer has been optimized to provide maximum power throughput. 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 TOP204Y or TOP226Y switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP2XX & D3 as well as proper thermal management of the clamp network are critical requirements for efficient and reliable operation. The TVS clamp VR1 may need to be modified based on actual end circuit temperature rise considerations. FIGURE 3A: TYPICAL APPLICATION CIRCUIT BR1 KBP04M 400V, 1.5A EMI FILTER F1 3.1A 250v 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) + 85-265Vac 50/60Hz C1 330 u F 400V C6 0.1uF 4 NEUT 3 ~ - C6 = 0.1uF 250Vac X2-Saftey Cap T1 POL-15033 1 CLAMP NETWORK VR1 BZY97C200 PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0330 33mHy EMI/RFI CMC T1 = POL-15033 MAIN SWITCHING TRANSFORMER L2 = VTP-01002 [email protected]([email protected]) INDUCTOR C15 .010uF VR3 BZY97C200 30K 5W D1 BYV26D VR2 BZY97C200 U3 D3 MBR10100 PROPERLY SIZED PRI 11,12 HEAT SINK 3 C2 + 3300uF 35V D2 1N4148 4 C 1 1/2 OF U3 A R3 49.9K 1% C R4 10.0K 1% 2 SEC 6 NEC2501-H L2 VTP-01002 8uH @ 4.0A R2 330 1W BIAS U1 POWER INT. TOP204Y/TOP226Y PROPERLY SIZED HEAT SINK SOURCE CONTROL R2 510 5 E 3 C5 47uF + DRAIN 1/2 OF U3 R1 6.2 C3 + 120uF 25V RTN 7,8 C4 0.1uF +15Vdc @ 3.33A SOFT START KELVIN CONNECT C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF Css + 4.7uF C8 2.2nF U2 1 C TL431 R A C9 0.1uF 8 6 HIGH VOLTAGE RETURN 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: POL-15033 REVISION: 08/28/03 DRAWN BY: PETER PHAM REF:TOP204,TOP226 SCALE: NONE SHEET: 2 OF 8 APPLICATION NOTES FOR 13.8V @ 4.00A Below is an 85 to 132Vac input high precision 56 watt application circuit utilizing Power Integrations TOP104 switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP1X4 & D3 as well as proper thermal management of the clamp network are critical requirements for efficient and reliable operation. The TVS clamp VR1 may need to be modified based on actual end circuit temperature rise considerations. PARAMETER MIN. FIGURE 3B CIRCUIT PARAMETERS: AC LINE VOLTAGE 47/400 Hz OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS OUTPUT CURRENT PEAK LINE REGULATION (85 TO 132Vac) LOAD REGULATION 10-100% RIPPLE SPEC LIMITS TYP. 85 0.0 ----------------------------- -------13.8 --------------0.20 0.20 50.0 MAX. UNITS 135 Vac Vdc Amps Amps +% +% +mV 4.00 4.50 ---------------------- FIGURE 3B: TYPICAL APPLICATION CIRCUIT BR1 KBP04M 400V, 1.5A EMI FILTER F1 3.1A 250v L1 PMCE-0330 1 33mHY 2 LINE ~ + HOT RAIL +110 to 190Vdc C1, 390.0 uF, 200V Nichicon # UVX2D391MPA, 85C Diameter=25mm (.984) Length=35mm (1.378) + 85-132Vac 50/60Hz C1 390 uF 200V C6 0.1uF 4 NEUT 3 ~ - C6 = 0.1uF 250Vac X2-Saftey Cap T1 POL-15033 1 C15 .010uF 1KV VR1 BZY97C200 POL-15033 VERSION 13.8V @ 4.00A PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0330 33mHy EMI/RFI CMC T1 = POL-15033 MAIN SWITCHING TRANSFORMER L2 = VTP-01002 [email protected]([email protected]) INDUCTOR VR3 BZY97C200 30K 5W D1 BYV26D MUR160 VR2 BZY97C200 U3 D3 MBR10100 PROPERLY SIZED PRI 11,12 HEAT SINK 3 C2 + 3300uF 35V D2 1N4148 4 C 1 1/2 OF U3 A R3 47.3K 1% C R4 10.50K 1% 2 SEC 6 NEC2501-H L2 VTP-01002 8uH @ 4.0A C3 + 120uF 25V RTN 7,8 C4 0.1uF +13.8Vdc @ 4.00A BIAS U1 POWER INT. PWR-TOP104YAI PROPERLY SIZED HEAT SINK SOURCE CONTROL R2 510 5 E 3 C5 47uF + DRAIN 1/2 OF U3 R1 6.2 SOFT START KELVIN CONNECT C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF Css + 4.7uF C8 2.2nF U2 C9 0.1uF 1 C TL431 R A 8 6 HIGH VOLTAGE RETURN 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: POL-15033 REVISION: 08/28/03 DRAWN BY: PETER PHAM REF:TOP204,TOP226 SCALE: NONE SHEET: 3 OF 8 APPLICATION NOTES FOR 13.8V @ 4.00A Below is an 85 to 265Vac input high precision 51 watt application circuit utilizing Power Integrations TOP204 switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP1X4 & D3 as well as proper thermal management of the clamp network are critical requirements for efficient and reliable operation. The TVS clamp VR1 may need to be modified based on actual end circuit temperature rise considerations. PARAMETER MIN. FIGURE 3C CIRCUIT PARAMETERS: AC LINE VOLTAGE 47/400 Hz OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS OUTPUT CURRENT PEAK LINE REGULATION (85 TO 132Vac) LOAD REGULATION 10-100% RIPPLE SPEC LIMITS TYP. MAX. 85 0.0 ----------------------------- -------12 --------------0.20 0.20 50.0 UNITS 265 Vac Vdc Amps Amps +% +% +mV 3.5 4.20 ---------------------- FIGURE 3C: TYPICAL APPLICATION CIRCUIT EMI FILTER F1 3.1A 250v LINE 1 L1 PMCE-0330 33mHY 2 BR1 KBP04M 400V, 1.5A ~ + HOT RAIL +110 to 375Vdc + POL-15033 VERSION 12V @ 4.00A PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0330 33mHy EMI/RFI CMC T1 = POL-15033 MAIN SWITCHING TRANSFORMER L2 = VTP-01002 [email protected]([email protected]) INDUCTOR 85-132Vac 50/60Hz C1 110 uF 200V C6 0.1uF 4 NEUT 3 ~ - C6 = 0.1uF 250Vac X2-Saftey Cap T1 POL-15033 1 C15 .010uF 1KV VR1 BZY97C200 VR3 BZY97C200 30K 5W D1 BYV26D MUR160 VR2 BZY97C200 U3 D3 MBR10100 PROPERLY SIZED PRI 11,12HEAT SINK 3 C2 + 3300uF 35V D2 1N4148 4 C 1 1/2 OF U3 A R3 38K 1% C R4 10.0K 1% 2 SEC 6 NEC2501-H L2 VTP-01002 8uH @ 4.0A C3 + 120uF 25V RTN 7,8 C4 0.1uF +12Vdc @ 4.00A BIAS U1 POWER INT. TOP204Y/TOP226Y PROPERLY SIZED HEAT SINK SOURCE CONTROL R2 510 5 E 3 C5 47uF + DRAIN 1/2 OF U3 R1 6.2 SOFT START KELVIN CONNECT C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF Css + 4.7uF C8 2.2nF U2 C9 0.1uF 1 C TL431 R A 8 6 HIGH VOLTAGE RETURN 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: POL-15033 REVISION: 08/28/03 DRAWN BY: PETER PHAM REF:TOP204,TOP226 SCALE: NONE SHEET: 4 OF 8