TABLE 1: ELECTRICAL SPECIFICATIONS AT 25 O C FIGURE 1: SCHEMATIC DIAGRAM SWITCHING TRANSFORMER DESIGNED FOR USE WITH POWER INTEGRATIONS PWR-TOP227Y. REFER TO APPLICATION CIRCUITS OF FIGURE 3. PARAMETER MIN. PRIMARY INDUCTANCE (3-1) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ 675 SPEC LIMITS TYP. 750 MAX. UNITS 825 µHY WHITE DOT DENOTES PIN #1 (HOT RAIL) 1 11,12 (+30V) PRIMARY TURN RATIO'S: SEC (11,12-7,8) : PRIMARY (3-1) BIAS (5-6) : PRIMARY (3-1) --------------- PRI LEAKAGE IND. (SEC SHORTED) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ 1:4.000 1:9.333 -------- 8.5 --------------- + 4% + 4% 12.0 µHY (DRAIN) 3 SECONDARY (+BIAS) 5 7,8 (+30V RETURN) BIAS (HOT RETURN) 6 HIPOT: 50/60Hz, 1 Minute Minimum PRIMARY TO SECONDARY BIAS TO SECONDARY FIGURE 3 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 3750 3750 --------------- --------------- Vrms Vrms 85 -------30.0 --------------0.20 0.20 50.0 265 Vac Vdc Amps Amps +% +% +mV 0.10 ----------------------------- 3.00 3.20 ---------------------- (1) REFER TO APPLICATION CIRCUIT OF FIGURE 3A. FOR 28.0V @ 4.0A, VOLTAGE DOUBLER VERSION REFER TO FIGURE 3B. 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. FIGURE 2: PHYSICAL DIMENSIONS mm (INCHES) 12 11 10 9 8 7 P POL-30030 M YYWW PIN #1 WHITE DOT 1 2 3 4 5 6 34.30 (1.350) MAX CORE TAPED 29.00 (1.142) MAX UL INSULATION SYMBOL AND MANUFACTURER IDENTIFICATION HERE 32.00 (1.260) MAX 1 2 3 5.00 (.197) 4 25.00 (.984) 5 0.8 DIA. (.032) 6 4.0 (.157) MIN EI33/29/13 -OR- EI33, 12-PIN VERTICAL BOBBIN UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSIONAL TOLERANCES ARE: DECIMALS ANGLES .X + .25 + 0 O 30' .XX + .15 DO NOT SCALE DRAWING 22.5 (.886) REV. 07/18/97 05/20/98 03/05/99 04/20/99 01/06/04 DESCRIPTION OF CHANGES UPDATED RELEASE ADDED SECOND APPLICATION CIRCUIT FIG. 3B & UL/CSA APPROVALS UPDATED TO UL CLASS (B) INSULATION SYSTEM CHANGED LEAKAGE INDUCTANCE FROM 16.0 MAX TO 12.0 MAX CORRECT PART NUMBER ON PAGE 2 & 3 FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-30030 REVISION: 01/06/04 DRAWN BY:PETER PHAM REF: PWR-TOP227Y SCALE: NONE SHEET: 1 OF 7 BY TO TO MD MD PP APPLICATION NOTES Premier Magnetics POL-30030 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 P0L-30030 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 90 watt application circuit utilizing Power Integrations PWR-TOP227 switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP227Y & D3 as well as proper thermal management & board layout are critical requirements for efficient and reliable operation. FIGURE 3: TYPICAL APPLICATION CIRCUIT PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0160 16mHy 1.5A EMI/RFI CMC T1 = POL-30030 MAIN SWITCHING TRANSFORMER L2 = VTP-01002 [email protected]([email protected]) INDUCTOR F1 3.1A 250v BR1 2KBP04M 400V, 2 .0A EMI FILTER LINE 1 ~ 2 + C1 470 uF 400V C6 0.1uF 4 NEUT HOT RAIL +100 to 375Vdc 3 ~ C1, 470.0 uF, 400V Nichicon # LLQ2G471MHSC, 85C Diameter=35mm (1.378) Length=40mm (1.575) + 85-265Vac 50/60Hz L1 PMCE-0160 16mHY ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: C1: > 400V, Ripple Rated > 790mA @ 120Hz @ Max. Operating Temp. (Nichicon P/N LLQ2G471MHSC, 85C) C2, C3: > 50V, IN PARALLEL Ripple Rated > 3500mA @ 100KHz @ Max. Op. Temp. (Panasonic P/N EEUFA1H102L, 105C) - C6 = 0.1uF 250Vac X2-Saftey Cap T1 POL-30030 1 VR1 = VR2 1N6298A (1.5KE130A) 11,12 3 C2,C3 + 1000uF 50V D2 1N4148 4 C + 1 1/2 OF U3 A R3 30.1K 1% C R4 2.74K 1% 2 SEC 5 NEC2501-H L2 VTP-01002 8uH @ 4.0A PROPERLY SIZED HEAT SINK PRI D1 MUR160 U3 D3 MUR620 + C4 470uF 50V RTN 7,8 C4 0.1uF +30Vdc @ 3.0A BIAS U1 POWER INT. TOP227Y PROPERLY SIZED HEAT SINK SOURCE SOURCE CONTROL C5 47uF + DRAIN 1/2 OF U3 R2 680 6 E 3 R5 390 1W R1 6.8 KELVIN CONNECT C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF 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 FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-30030 REVISION: 01/06/04 DRAWN BY:PETER PHAM REF: PWR-TOP227Y SCALE: NONE SHEET: 2 OF 7 APPLICATION NOTES FOR 28.0V @ 4.00A Below is voltage doubler input high precision 112 watt application circuit utilizing Power Integrations TOP227Y switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP227 & D3 as well as proper thermal management of the clamp network are critical requirements for efficient and reliable operation. SPEC LIMITS TYP. PARAMETER MIN. FIGURE 3B CIRCUIT PARAMETERS: OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS OUTPUT CURRENT PEAK LINE REGULATION (85 TO 132Vac) LOAD REGULATION 10-100% RIPPLE 0.50 ----------------------------- 28.0 --------------0.20 0.30 50.0 MAX. UNITS 4.00 4.20 ---------------------- Vdc Amps Amps +% +% +mV FIGURE 3B: TYPICAL APPLICATION CIRCUIT PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0160 16mHy 1.5A EMI/RFI CMC T1 = POL-30030 MAIN SWITCHING TRANSFORMER L2 = VTP-01005 [email protected] INDUCTOR ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: C1: > 400V, Ripple Rated > 740mA @ 120Hz @ Max. Operating Temp. (Nichicon P/N LLQ2G471MHSC, 85C) C2, C3: > 50V, IN PARALLEL Ripple Rated > 3000mA @ 100KHz @ Max. Op. Temp. (Panasonic P/N EEUFA1H102L, 105C) S1 CLOSED FOR 115V INPUT 120/220Vac 50/60Hz C1 0.01uF, Y 2 GND C2 0.01uF, Y 2 1 C3 0.47uF X2 L1 PMCE-0160 16mHY 2 4 + R2 330K ~ - R3 330K 3 CLAMP NETWORK D3 MUR620 1 VR3 P6KE200A 8K 10W D1 MUR160 VR2 P6KE200A U3 5 C7 0.1uF + SEC C R4 4.64K 1% +28Vdc @ 4.0A + C4 470uF 50V RTN R2 680 3 C8 47uF R3 47.3K 1% 7,8 6 E 1 1/2 OF U3 A 2 BIAS 1/2 OF U3 + SOURCE C2,C3 + 1000uF 50V D2 1N4148 C DRAIN 11,12 3 4 L2 VTP-01005 10uH @ 5.0A PROPERLY SIZED HEAT SINK PRI NEC2501-H U1 POWER INT. TOP 227Y PROPERLY SIZED HEAT SINK C6 470 uF 200V T1 POL-30030 C15 0.10uF VR1 P6KE200A C5 470 uF 200V C4 0.01uF X2 R1 300K 1/2W NEUT ~ + LINE HOT RAIL +210 to 375Vdc + F1 3.1A 250v BR1 DF04M 400V, 1.0A R5 390 1W R4 6.2 KELVIN CONNECT 1 CONTROL U2 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 FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-30030 REVISION: 01/06/04 DRAWN BY:PETER PHAM REF: PWR-TOP227Y SCALE: NONE SHEET: 3 OF 7