TABLE 1: ELECTRICAL SPECIFICATIONS AT 25 OC SWITCHING TRANSFORMER DESIGNED FOR USE WITH POWER INTEGRATIONS TOP221Y. REFER TO APPLICATION CIRCUIT OF FIGURE 3. PARAMETER MIN. PRIMARY INDUCTANCE (2-1) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ 3.4 SPEC LIMITS TYP. MAX. 4.0 4.6 FIGURE 1: SCHEMATIC DIAGRAM DOT ON BOBBIN DENOTES PIN #1 UNITS mHY (HOT RAIL) 1 PRIMARY TURN RATIO'S: SEC (9-6) : PRIMARY (2-1) BIAS (3-4) : PRIMARY (2-1) PRI LEAKAGE IND. (SEC SHORTED) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ --------------- 1:12.167 -------1: 9.125 -------- + 3% + 3% -------- -------- µHY 160 9 (+9.75V) (DRAIN) 2 SECONDARY (+13.2V) 3 6 (COM) 13.2V BIAS (BIAS RETURN)4 HIPOT: PRIMARY & BIAS TO SECONDARY PRIMARY TO BIAS 3000 600 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 20-100% RIPPLE 85 -------20 ----------------------------- --------------- --------------- Vrms Vrms 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) UL CLASS (B) 130 INSULATION SYSTEM PM130-R1, PM130-H1, PM130-H1A (UL FILE #E177139) OR ANY UL (1) REFER TO PRECICION OPTO-COUPLED APPLICATION CIRCUIT OF FIGURE 3. AUTHORIZED CLASS (B) INSULATION SYSTEM. FIGURE 4. SHOWS A LOWER COST BIAS REGULATED CIRCUIT WHICH WILL HAVE 10% LINE LOAD REGULATION TYPICAL. FIGURE 2: PHYSICAL DIMENSIONS mm (INCHES) 10 9 8 7 6 -------9.75 --------------0.50 0.50 50.0 265 -------500 550 ---------------------- Vac Vdc mA mA +% +% +mV 5 P POL-97505 M YYWW PIN #1 WHITE DOT 1 2 3 4 18.2 (.716) MAX UL INSULATION SYMBOL AND MANUFACTURER IDENTIFICATION HERE 16.5 (.650) MAX 3.5 (.138) 1 10.5 (.413) 2 3 4 17.6 (.693) MAX 12.5 (.492) 6.0 (.236) TYP 4.5 (.177) TYP 0.6 DIA. (.024) 12.2 (.480) REV. 04/23/98 07/30/99 10 9 8 2.7 (.106) 7 6 5 13.5 (.531) DESCRIPTION OF CHANGES UPDATED TO ALLOW EITHER BIAS OR OPTO-COUPLER FEEDBACK UPDATE TO UL CLASS (B) 130 INSULATION SYSTEM EE16/EI16, 10-PIN VERTICAL 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 FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-97505 REVISION: 07/30/99 DRAWN BY: TOM O'NEIL REF: TOP221Y SCALE: NONE SHEET: 1 OF 7 BY TO MD PRECISION OPTO-COUPLED CIRCUIT APPLICATION NOTES Premier Magnetics POL-97505 Switch Mode Transformer was designed for use with Power Integrations, Inc. TOP221Y 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-97505 transformer has been optimized to provide maximum power throughput. The 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 4.8 watt application circuit utilizing Power Integrations TOP221Y switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. FIGURE 3: TYPICAL APPLICATION CIRCUIT PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCU-0330 33mHy EMI/RFI CMC T1 = POL-97504 MAIN SWITCHING TRANSFORMER L2 = VTP-01001 10uHy, 1.0Amp INDUCTOR BR1 DF06M 600V, 1A EMI FILTER F1 3.1A 250v LINE 1 ~ 2 + 4 NEUT HOT RAIL +100 to 375Vdc C1 22 uF 400V C6 0.1uF 3 ~ +9.75V OUTPUT: C2 >16V, Ripple Rated > 550mA @ 100KHz @ Max. Op. Temp. PANASONIC FA SERIES: LOW IMPEDANCE LONG LIFE RADIAL SERIES C2 = 270uF, 16V = PANASONIC EEUFA1C271 C3 = 220uF, 16V = PANASONIC ECA1CFG221 C1, 22.0 uF, 400V Low Profile Type: Nichicon # UVS2G220MRA, 85C Nichicon # URT2G220MRA, 105C Diameter=18mm (.708) Length=20mm (.787) + 85-265Vac 50/60Hz L1 PMCU-0330 33mHY ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: - C6 = 0.1uF 250Vac X2-Saftey Cap CLAMP NETWORK 1 VR1 P6KE200A L2 VTP-01001 10uH @ 1.0A D3 MBR160 PRI D1 MUR160 (BYV26C) U3 NEC PS2501-1 T1 POL-97505 +9.75Vdc @ 500mA 9 2 C2 + 270uF 16V D2 1N4148 C R3 13.7K 1% C R4 4.75K 1% 2 SEC 3 4 1 1/2 OF U3 A RTN 6 C4 0.1uF C3 + 220uF 16V BIAS U1 POWER INT. TOP221Y SOURCE R2 220 4 E 3 C5 47uF + DRAIN 1/2 OF U3 R5 330 1/2W R1 6.2 KELVIN CONNECT CONTROL PROPERLY SIZED HEAT SINK REQUIRED C7 & C8 = 250Vac Y-SAFTEY CAPS EMI FILTER C7 2.2nF 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 FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-97505 REVISION: 07/30/99 DRAWN BY: TOM O'NEIL REF: TOP221Y SCALE: NONE SHEET: 2 OF 7 LOW COST BIAS REGULATED CIRCUIT APPLICATION NOTES Premier Magnetics POL-97505 Switch Mode Transformer was designed for use with Power Integrations, Inc. TOP221Y 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-97505 transformer has been optimized to provide maximum power throughput. The 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 Dual Output 4.8 watt application circuit utilizing Power Integrations TOP221 switching regulator in the flyback buck-boost configuration. This circuit provide a nominal output of 9.75Vdc at 250mA continuous and capable of 550mA peak for short periods of time. This circuit represents the lowest cost implementation and utilizes the bias winding for feedback control. As such the line & load regulation are worse than that which could be achieved by utilizing an opto-coupler to sense the actual output. Please refer to page 2 of this application note for the high precision opto-coupler version. The component values listed are intended for reference purposes only. FIGURE 4: TYPICAL APPLICATION CIRCUIT PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCU-0330 33mHy EMI/RFI CMC T1 = POL-97504 MAIN SWITCHING TRANSFORMER L2 = VTP-01001 10uHy, 1.0Amp INDUCTOR BR1 DF06M 600V, 1A EMI FILTER F1 3.1A 250v LINE 1 2 ~ + 4 NEUT 3 HOT RAIL +100 to 375Vdc C1 22 uF 400V C6 0.1uF ~ +9.75V OUTPUT: C2 >16V, Ripple Rated > 550mA @ 100KHz @ Max. Op. Temp. PANASONIC FA SERIES: LOW IMPEDANCE LONG LIFE RADIAL SERIES C2 = 270uF, 16V = PANASONIC EEUFA1C271 C3 = 220uF, 16V = PANASONIC ECA1CFG221 C1, 22.0 uF, 400V Low Profile Type: Nichicon # UVS2G220MRA, 85C Nichicon # URT2G220MRA, 105C Diameter=18mm (.708) Length=20mm (.787) + 85-265Vac 50/60Hz L1 PMCU-0330 33mHY ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: - C6 = 0.1uF 250Vac X2-Saftey Cap CLAMP NETWORK VR1 P6KE200A D1 MUR160 (BYV26C) 1 T1 POL-97505 D3 MBR160 PRI U1 POWER INT. TOP221Y 2 C2 + 270uF 16V SOURCE SEC 3 6 C4 0.1uF C3 + 220uF 16V RTN BIAS 4 + DRAIN C5 47uF 10V VR2 1N5236B 7.5V +9.75Vdc @ 500mA 9 D2 1N4148 R1 47Ω L2 VTP-01001 10uH @ 1.0A KELVIN CONNECT CONTROL PROPERLY SIZED HEAT SINK REQUIRED C7 & C8 = 250Vac Y-SAFTEY CAPS EMI FILTER C7 2.2nF C8 2.2nF 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 FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-97505 REVISION: 07/30/99 DRAWN BY: TOM O'NEIL REF: TOP221Y SCALE: NONE SHEET: 3 OF 7