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 PRIMARY INDUCTANCE (2-1) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ WHITE DOT ON BOBBIN DENOTES PIN #1 SPEC LIMITS MIN. TYP. MAX. UNITS 900 µHY 950 1000 1 PRIMARY 2 TURN RATIO'S: SEC (9,10-6,7) : PRIMARY (2-1) BIAS (4-5) : PRIMARY (2-1) PRI LEAKAGE IND. (SEC SHORTED) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ HIPOT: PRIMARY TO SECONDARY BIAS TO SECONDARY --------------- 1: 3.58 1:13.60 --------------- + 3% + 3% -------- 14.0 18.0 µHY 10 3 4 SECONDARY TRIPLE INSULATED WIRE 6 BIAS 5 3000 3000 --------------- --------------- Vrms Vrms 85 265 1.2 1.5 ---------------------- Vac Vdc Amps Amps +% +% +mV -------- 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 0.0 ----------------------------- -------45.0 --------------0.20 0.20 50.0 TRANSFORMER TEMP RISE: 115Vac FULL LOAD -------- 40 O C PRIMARY PIN#3 MUST BE LEFT OPEN, UNUSED IN CIRCUIT 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 3. FIGURE 2: PHYSICAL DIMENSIONS mm (INCHES) 10 9 8 7 6 P POL-45012 M YYWW PIN #1 WHITE DOT 1 2 3 4 5 28.5 (1.122) MAX 25.5 (1.004) MAX UL INSULATION SYMBOL AND MANUFACTURER IDENTIFICATION HERE 24.2 (.953) MAX 1 2 3 5.0 (.197) 4 0.8 DIA. (.032) 5 4.0 (.157) MIN 17.5 (.689) 20.0 (.787) REV. DESCRIPTION OF CHANGES BY 10/26/95 04/29/99 UPDATED RELEASE UPDATE TO UL CLASS (B) 130 INSULATION SYSTEM TO MD EE (EI) 28/11, 10-PIN VERTICAL BOBBIN 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: POL-45012 REVISION: 10/26/95 DRAWN BY: TOM O'NEIL REF: PWR-TOP204YAI SCALE: NONE SHEET: 1 OF 4 APPLICATION NOTES Premier Magnetics' POL-45012 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%. Premiers' POL-45012 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 54 watt application circuit utilizing Power Integrations PWR-TOP204 switching regulator in the flyback buck-boost configuration. Special care must be taken to properly heat sink U1. The Soft Start capacitor C11 provides sufficient time for the Hot Rail voltage to be stable before switching begins. R2 provides a discharge path for C11 when power is removed. The component values listed are intended for reference purposes only. FIGURE 3: TYPICAL APPLICATION CIRCUIT F1 3.15A LINE 85-265Vac 50/60Hz L1 PMCE-0330 33mHY 1 2 C6 0.1uF 4 PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0330 33mHy EMI/RFI COMMON MODE CHOKE T1 = POL-45012 MAIN SWITCHING TRANSFORMER L2 = VTP-01002 10uHy, 2.0Amp INDUCTOR +118-375Vdc BR1 Vrrm = 400V Io = 1.5A (FAGOR FBP04) 3 C6 = 0.1uF 250Vac X2-Saftey Cap C1 220.0 uF 400V 1 CLAMP NETWORK VR1 P6KE200A + NEUT EMI FILTER 10 2 D3 1N4148 4 + DRAIN POWER INT. PWR-TOP SOURCE 204YAI R5 2.94K 1% + C3 470uF 63V 5 U3 1 MOC8102 C4 0.1uF BIAS R3 6.2 +45Vdc @ 1.2A RTN 6 NOTE: PIN #3 MUST BE LEFT OPEN C5 47uF R4 49.9K 1% SECONDARY T1 POL-45012 U1 L2 VTP-01002 10uH @ 2.0A D2 MUR810 C2 + 1000uF 63V PRI 3 D1 MUR160 C1, 220.0 uF, 400V Low Profile Type: Nichicon # LLQ2G221MHSB, 85C Diameter=30mm (1.181) Length=30mm (1.181) 5 C C E 4 KELVIN CONNECT R2 3.9K A 2 R1 1K CONTROL C10 0.1uF SOFT START C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF C8 2.2nF C11 22uF 50V + 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: POL-45012 REVISION: 10/26/95 DRAWN BY: TOM O'NEIL REF: PWR-TOP204YAI SCALE: NONE SHEET: 2 OF 4