TABLE 1: ELECTRICAL SPECIFICATIONS AT 25 OC PARAMETER MIN. PRIMARY INDUCTANCE (3-1) FREQ. = 100 KHZ @ 0.250Vrms 550 SPEC LIMITS TYP. MAX. 600 FIGURE 1: SCHEMATIC DIAGRAM WHITE DOT ON TOP OF BOBBIN DENOTES PIN #1 UNITS 1 µHY 650 10 (+24 VDC@150mA) SECONDARY #2 PRIMARY TURN RATIO'S: SEC #1 (7-6) : PRIMARY (3-1) SEC #2 (10-9) : PRIMARY (3-1) BIAS (4-5) : PRIMARY (10-9) PRI LEAKAGE INDUCTANCE SECONDARIES SHORTED FREQ. = 100 KHZ @ 0.250Vrms ---------------------- 1: 8.4 1: 2.0 1: 3.82 -------- -------- ---------------------- + 3% + 3% + 3% 3 10 µHY 4 9 7 (+5VDC@800mA) SECONDARY #1 BIAS 6 5 HIPOT: PRIMARY & BIAS TO SECONDARY PRIMARY TO BIAS SECONDARY#1 TO SECONDARY#2 3000 500 500 APP CIRCUIT PARAMETERS: SEE FIGURE 3 AC LINE VOLTAGE 47/400 Hz OPTION: DC INPUT (HOT RAIL) SEC #1 OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS SEC #2 OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS 85 48 50 20 ---------------------- --------------+5 -------+ 24 -------- ---------------------- 265 375 Vrms Vrms Vrms Vac Vdc Vdc mA Vdc mA +800 150 NOTE1: REINFORCED INSULATION, UL1950, IEC950, CSA-950: A) ALL MATERIALS MEET "UL", "CSA" & "IEC" REQUIREMENTS B) ALL MATERIALS RATED 130 OC (CLASS B) OR BETTER. C)TRIPLE INSULATED SECONDARY. D)DESIGNED FOR >6.2mm CREEPAGE REQUIREMENTS. E) VARNISH FINISHED ASSEMBLY. 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 10 9 8 7 6 UL INSULATION SYMBOL AND MANUFACTURER IDENTIFICATION HERE P TSD-1406 M YYWW PIN #1 WHITE DOT 1 2 3 4 NOTE2: A) BOTTOM HALF OF CORE IS CUFF WRAPPED PRIOR TO ASSEMBLY. THIS GAURANTEES >6.2mm CREEPAGE PIN-CORE-PIN 5 23.0 (.906) MAX 18.0 (.709) MAX .125 (3.2) MIN 21.00 (.827) MAX 7.1 (.28) MYLAR TAPE 8mm WIDE 1 2 3 4 0.8 DIA. (.030) 5 4.0 (.160) CUFF WRAP BOTTOM HALF OF CORE 6.0 (.240) TYP 16.0 (.630) 12.0 (.470) BOTTOM HALF OF CORE IS CUFF WRAPPED WITH MYLAR TO GUARANTEE 6.2mm PIN-CORE-PIN CREEPAGE REV. 05/11/99 06/09/99 07/28/99 09/23/99 01/19/01 02/12/01 DESCRIPTION OF CHANGES UPDATE RELEASE CHANGED DESIGN TO 24V OUTPUT UPDATE LEAKAGE INDUCTANCE FROM TBD TO 10uH CORRECT PIN NUMBER ON TEST SPEC. UPDATE TO UL CLASS (B) 130 INSULATION SYSTEM ADDED UL RECOGNIZED SYMBOL - NO OTHER CHANGES E22/19/6, 10-PIN E22 VERTICAL BOBBIN P Premier M Magnetics Inc. "INNOVATORS IN MAGNETICS TECHNOLOGY" 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: TSD-1406 REVISION: 02/12/01 DRAWN BY: PETER PHAM REF: TOP-223P SCALE: NONE SHEET: 1 OF7 BY PP PP PP PP MD MD APPLICATION NOTES Premier Magnetics' TSD-1406 Switch Mode Transformer was designed for use with Power Integrations, Inc. TOP223P three terminal off-line PWM switching regulator in a low cost Isolated Flyback Buck-Boost circuit configuration. The feedback implementation is accomplished indirectly by regulating the bias winding voltage. This is the lowest cost topology but has the drawback of poor load regulation. As such this topology is intended for use where load power is fairly constant. Resistor R2 provides an output clamp to prevent output voltage runaway and possible circuit damage under a no load condition. 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 switch mode controlled DC power source. These switching regulators provide a very simple solution to off-line designs. The inductors and transformer used with the 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 8 watt application circuit utilizing Power Integrations TOP223P switching regulator in the isolated flyback buck-boost configuration. The component values listed are intended for reference purposes only. FIGURE 3: TYPICAL APPLICATION CIRCUIT ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: +5V OUTPUT: C2 > 10V, Ripple Rated > 980mA @ 100KHz @ Max. Op. Temp. +24V OUTPUT: C4 > 35V, Ripple Rated > 150mA @ 100KHz @ Max. Op. Temp. PANASONIC HFG SERIES: LOW IMPEDANCE RADIAL SERIES C2 = 2200uF, 10V = PANASONIC ECA1AFG222 C3 = 100uF, 10V = PANASONIC ECA1AFG101 C4 = 47uF, 35V = PANASONIC ECA1VFG470 C5 = 33uF, 35V = PANASONIC ECA1VFG330 PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCU-0220 22mHy EMI/RFI CMC T1 = TSD-1406 MAIN SWITCHING TRANSFORMER L2 = VTP-01001 10uHy, 1.0Amp INDUCTOR F1 1.5A 250v BR1 DF06S 600V, 1.0A EMI FILTER LINE 1 ~ 2 + C1 22 uF 400V C6 0.1uF 4 NEUT HOT RAIL +48 to 375Vdc 3 ~ - C6 = 0.1uF 250Vac X2-Saftey Cap 1 VR1 P6KE200A 4 D C N/C N/C N/C N/C S L2 VTP-01001 D4 MUR405 7 4 C11 0.1uF C2 + 2200uF 10V BIAS DRAIN + RTN 9 D2 1N4148 C 1/2 OF U3 C5 33uF 35V + SEC #2 3 NEC2501-H U1 POWER INT. PWR-TOP223P +24Vdc @ .150A C4 47uF 35V PRI D1 MUR160 L3 VTP-01001 D3 MUR130 T1 10 TSD-1406 CLAMP NETWORK U3 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-5330 22mHY 5 E R3 10.0K 1% C3 + 100uF 10V RTN R1 75 + C12 47uF SOURCE C 6 CONTROL S R2 10.0K 1% 2 SEC #1 3 1 1/2 OF U3 A +5Vdc @ .800A C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF C8 2.2nF U2 1 C TL431 R A 6 C9 0.1uF 8 HIGH VOLTAGE RETURN P Premier M Magnetics Inc. "INNOVATORS IN MAGNETICS TECHNOLOGY" 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: TSD-1406 REVISION: 02/12/01 DRAWN BY: PETER PHAM REF: TOP-223P SCALE: NONE SHEET: 2 OF7 APPLICATION NOTES Below is voltage doubler input high precision 8 watt application circuit utilizing Power Integrations TOP223P switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP223P as well as proper thermal management of the clamp network are critical requirements for efficient and reliable operation. PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCU-0220 22mHy EMI/RFI CMC T1 = TSD-1406 MAIN SWITCHING TRANSFORMER L2 = VTP-01001 10uHy, 1.0Amp INDUCTOR ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: +5V OUTPUT: C2 > 10V, Ripple Rated > 980mA @ 100KHz @ Max. Op. Temp. +24V OUTPUT: C4 > 35V, Ripple Rated > 150mA @ 100KHz @ Max. Op. Temp. PANASONIC HFG SERIES: LOW IMPEDANCE RADIAL SERIES C2 = 2200uF, 10V = PANASONIC ECA1AFG222 C3 = 100uF, 10V = PANASONIC ECA1AFG101 C4 = 47uF, 35V = PANASONIC ECA1VFG470 C5 = 33uF, 35V = PANASONIC ECA1VFG330 S1 CLOSED FOR 115V INPUT 120/220Vac 50/60Hz GND C1 0.01uF, Y2 C2 0.01uF, Y2 L1 PMCE-0160 16mHY 1 C3 0.47uF X2 2 + R2 330K ~ - R3 330K 4 3 T1 10 TSD-1406 CLAMP NETWORK U3 3 4 N/C N/C N/C N/C S + RTN 7 L2 VTP-01001 D4 MUR405 4 C11 0.1uF C2 + 2200uF 10V BIAS C C5 33uF 35V + 9 D2 1N4148 C D +24Vdc @ .150A SEC #2 NEC2501-H 1/2 OF U3 L3 VTP-01001 C4 47uF 35V PRI D1 MUR160 DRAIN C1A 22 uF 200V D3 MUR130 1 VR1 P6KE200A U1 POWER INT. PWR-TOP223P C1 22 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 5 E 3 CONTROL 1 1/2 OF U3 A R2 10.0K 1% C R3 10.0K 1% 2 SEC #1 +5Vdc @ .800A C3 + 100uF 10V RTN 6 R1 75 + C12 47uF 1 U2 C TL431 R S SOURCE A 6 C9 0.1uF 8 HIGH VOLTAGE RETURN P Premier M Magnetics Inc. "INNOVATORS IN MAGNETICS TECHNOLOGY" 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: TSD-1406 REVISION: 02/12/01 DRAWN BY: PETER PHAM REF: TOP-223P SCALE: NONE SHEET: 3 OF7