POL-15033 - Premier Magnetics

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