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. PFC FRONT END. PARAMETER PRIMARY INDUCTANCE (2-1) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ 1 SPEC LIMITS MIN. TYP. MAX. UNITS 990 µHY 1100 WHITE DOT ON BOBBIN DENOTES PIN #1 1210 PRIMARY 2 9,10 SECONDARY 4 TURN RATIO'S: SEC (9,10-6,7) : PRIMARY (2-1) BIAS (3-4) : PRIMARY (2-1) PRI LEAKAGE IND. (SEC SHORTED) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ HIPOT: PRIMARY TO SECONDARY BIAS TO SECONDARY APP CIRCUIT PARAMETERS: (1) DC INPUT VOLTAGE OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS OUTPUT CURRENT PEAK LINE REGULATION (85 TO 265Vac) LOAD REGULATION 10-100% RIPPLE --------------- 1:14.67 1:8.80 --------------- + 3% + 3% -------- 22.0 25.0 µHY 3000 3000 --------------- --------------- Vrms Vrms 300 -------8.5 --------------0.20 0.20 50.0 375 Vac Vdc Amps Amps +% +% +mV 0.0 ----------------------------- 4.0 4.5 ---------------------- BIAS 6,7 5 SECONDARY PINS #9 & 10, #6 & 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 3. FIGURE 2: PHYSICAL DIMENSIONS mm (INCHES) 10 9 8 7 6 P TSD-794 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. 12/06/95 01/18/96 05/14/99 DESCRIPTION OF CHANGES ORIGINAL RELEASE INCREASED PRIMARY INDUCTANCE UPDATED TO UL CLASS (B) 130 INSULATION SYSTEM BY TO TO MD EE, EI28/11, 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: TSD-794 REVISION: 05/14/99 DRAWN BY: TOM O'NEIL REF: PWR-TOP204YAI SCALE: NONE SHEET: 1 OF 6 APPLICATION NOTES Premier Magnetics' TSD-794 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' TSD-794 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 high precision 35 watt application circuit utilizing Power Integrations PWR-TOP204 switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. The soft start capacitor Css is optional depending on the specific application. Simpler topology is possible depending on the line/load regulation required. FIGURE 3: TYPICAL APPLICATION CIRCUIT +290 to 375Vdc >> PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) T1 = TSD-794 MAIN SWITCHING TRANSFORMER L2 = VTP-01005 10uHy, 5.0Amp INDUCTOR HOT RETURN >> D2 MUR1610CT CLAMP NETWORK 1 VR1-A P6KE160A VR1-B P6KE160A 9,10 R4 23.7K 1% R5 10.0K 1% SECONDARY 2 T1 TSD-794 PROPERLY SIZED HEAT SINK C2 + 1000uF 25V PRI D1 MUR160 L2 VTP-01005 10uH @ 5.0A + DRAIN POWER INT. PWR-TOP SOURCE 202YAI C5 47uF D3 1N4148 U3 4 C C E 3 KELVIN CONNECT 2 R1 510 CONTROL PROPERLY SIZED HEAT SINK SOFT START EMI FILTER C7 2.2nF P Premier M Magnetics Inc. R2 200 1/2W A 5 HIGH VOLTAGE RETURN 1 NEC2501-H C4 0.1uF BIAS R3 6.2 + C3 470uF 16V RTN 6,7 4 U1 +8.5Vdc @ 4.0A C8 2.2nF Css 4.7uF + 1 U2 C TL431 R A C9 0.1uF 8 6 C7 & C8 = 250Vac Y-SAFTEY CAPACITORS 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: TSD-794 REVISION: 05/14/99 DRAWN BY: TOM O'NEIL REF: PWR-TOP204YAI SCALE: NONE SHEET: 2 OF 6