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设计范例报告
标题
使用HiperTFSTM-2 TFS7703H设计的190 W
连续功率、280 W峰值功率DC-DC正激式
转换器，待机工作频率为132 kHZ
规格
380 VDC输入；12 V，15 A主输出和12 V，
0.83 A待机输出
应用
一体机(AIO) PC电源
作者
应用工程部
文档编号
DER-368
日期
2013年11月12日
修订版本
7.1
特色概述
• 高效率集成式主转换器及待机转换器
• 集成的高端驱动器
• 内置的主及待机欠压锁存
• 伏秒限制为主变压器提供保护
• 单一的待机功率限制与输入电压变化关系
• 132 kHz的工作频率允许使用较小的主变压器(EF25)
• >91%的高效率主转换器
专利信息
此处介绍的产品和应用（包括产品之外的变压器结构和电路）可能包含一项或多项美国及国外专利，或正在申请的
美国或国外专利。有关Power Integrations专利的完整列表，请参见www.powerint.com。Power Integrations按照在
<http://www.powerint.com/ip.htm>中所述规定，向客户授予特定专利权利的许可。
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
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www.powerint.com
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
目录
1
2
3
4
5
6
7
8
简介.............................................................................................................................4
电源规格 .....................................................................................................................6
电路原理图 ..................................................................................................................7
电路描述 .....................................................................................................................8
PCB 布局 ..................................................................................................................11
物料清单(BOM) .........................................................................................................13
设计表格 ...................................................................................................................15
主变压器(T1)规格 ......................................................................................................24
8.1
电气原理图 .........................................................................................................24
8.2
电气规格 ............................................................................................................24
8.3
材料 ...................................................................................................................24
8.4
结构图 ................................................................................................................25
8.5
制作说明 ............................................................................................................27
9 输出电感(L1)规格 ......................................................................................................28
9.1
电气原理图 .........................................................................................................28
9.2
电气规格 ............................................................................................................28
9.3
材料 ...................................................................................................................28
10
待机电源变压器(T2)规格 .......................................................................................29
10.1
电气原理图 .....................................................................................................29
10.2
电气规格 .........................................................................................................29
10.3
材料 ................................................................................................................29
10.4
结构图 ............................................................................................................30
10.5
制作说明 .........................................................................................................30
11
散热片组件 ............................................................................................................31
11.1
初级金属散热片 ..............................................................................................31
11.2
完成的初级散热片 ..........................................................................................32
11.3
初级散热片装配 ..............................................................................................33
11.4
次级金属散热片 ..............................................................................................34
11.5
完成的次级散热片 ..........................................................................................35
11.6
次级散热片装配 ..............................................................................................36
12
性能测量 ................................................................................................................37
12.1
效率 ................................................................................................................37
12.2
待机空载输入功率 ..........................................................................................41
12.3
调整 ................................................................................................................42
12.4
波形 ................................................................................................................44
12.5
主输出二极管峰值反向电压 ............................................................................45
12.6
启动和维持 .....................................................................................................47
12.7
纹波 ................................................................................................................49
12.7.1 纹波测量方法 ..............................................................................................49
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第2页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
12.7.2 纹波测量结果 .............................................................................................. 50
12.8
瞬态响应 ........................................................................................................ 51
13
热测试 ................................................................................................................... 53
13.1
热图片 ............................................................................................................ 54
13.2
主输出整流管的热电耦测量 ............................................................................ 56
14
增益相位图 ............................................................................................................ 57
15
版本历史................................................................................................................ 58
重要说明：
虽然本电路板的设计满足安全隔离要求，但工程原型尚未获得机构认证。
第3页（共59页）
Power Integrations
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DER-368：使用TFS7703H设计的190 W一体机PC电源
1 简介
本文档是介绍一款190 W连续功率、280 W峰值功率电源的初步测试的工程报告，该电源
由一个双管正激主转换器和一个反激待机转换器构成，它采用工作频率为132 kHz 的
TFS7703H IC设计而成。一个EF25变压器用于主输出电源，一个EE16变压器用于待机电
源。测试的目的是为了确定一个用于PC电源（仅）12 V输出“一体化”解决方案的评估板
所能实现的最大输出功率（带风冷）。
主转换器在300 VDC至420 VDC的输入电压范围内进行工作。待机转换器的输入工作电压
范围则为120 VDC至420 VDC。在典型系统中，高压DC输入通常由PFC级提供。
本文档包括电源规格、电路原理图、物料清单、变压器规格文件、测试设置说明及性能
数据。
Figure 1 – DER-368 Populated Circuit Board Photograph, Top View.
Power Integrations, Inc.
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第4页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
Figure 2 – DER-368 Populated Circuit Board Photograph, Bottom View.
第5页（共59页）
Power Integrations
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DER-368：使用TFS7703H设计的190 W一体机PC电源
2 电源规格
下表所列为设计的最低可接受性能。实际性能可参考测量结果部分。
说明
输入
直流总线电压
符号
VIN
最小值 典型值 最大值
300
380
420
单位
备注
VDC
仅直流输入
空载输入功率(380 VDC)
0.3
W
启动电压
关断电压
输出
输出1电压
输出1峰-峰值纹波电压
输出1电流
输出2电压
输出2峰-峰值纹波电压
输出2电流
总输出功率
连续输出功率
340
285
VDC
VDC
峰值输出功率
VSTART
VSTOP
VOUT1
VRIPPLE1
IOUT1
VOUT2
VRIPPLE2
IOUT2
11.4
12
0
11.4
0.83
V
mV
A
V
mV
A
190
W
12
0
POUT
12.6
120
15
12.6
120
280
POUT_PEAK
W
±5%
20 MHz带宽
22.5 A峰值
±5%
20 MHz带宽
（主12 V输出上的峰值负载为
22.5 A）
在25oC、380 VDC输入下测得
效率
20%负载
η
86
%
50%负载
η
90
%
100%负载
η
90
%
109 x 84 x 33
mm
长x宽x高
°C
强制风冷
尺寸
环境温度
tAMB
0
Power Integrations, Inc.
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40
第6页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
3 电路原理图
Figure 3 – Schematic.
第7页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
4 电路描述
图3中的电路原理图描述的是使用TFS7703H实现的一个12 V、15 A正激DC-DC转换器和
一个12 V、0.83 A反激待机/初级偏置电源。
HiperTFS-2 TFS7703H以高成本效益的方式将一个下管725 V主MOSFET、一个上管530 V
主MOSFET和一个725 V待机MOSFET、主及待机控制器、一个上管驱动器以及热关断
和其他故障保护和控制电路集成到同一个封装内。该器件非常适合具有主及待机转换器
（如PC电源）的高功率应用。待机转换器可以在宽输入电压范围内进行工作。主转换器用
于接受来自功率因数校正级的升压输入电压，通常在300 VDC至385 VDC的电压范围内进
行工作。
4.1
功率输入和滤波电路
本电路适用于主输出功率最高达180 W的PC电源。二极管D13可使保险丝F1在反向输入电
压连接时断开，从而避免发生严重故障。电容C1为大容量储能元件。
4.2
初级侧
元件C2、R6和VR3形成一个关断箝位电路，用于限制待机转换器漏极和主正激转换器下管
MOSFET漏极共用的U6的漏极电压。齐纳二极管VR3提供限定的箝位电压，并维持电容
C2上的最大电压(150 V)。大部分漏感能量和磁化能量都会返回转换器，这是因为阻断二极
管D3和D4具有慢恢复特性。主转换器与待机转换器共用一个复位/漏感尖峰箝位电路，
有助于减少元件数。待机转换器通过二极管D3和电阻R5连接到箝位电路，主转换器通
过D8、D4及R7连接到箝位电路。在复位时，主转换器会连接到一个远高于VIN 的复位
电压，因此主转换器的工作占空比可以超出50%以上，这样能在不影响维持时间的情况下
降低RMS开关电流。
旁路(BP)引脚与电容C12为HiperTFS-2控制器提供一个去耦工作电压。C12的值(10 µF)还
可以将主转换器的工作频率选定在132 kHz。启动时，旁路电容从IC U6内部的电流源进行
充电。当BP引脚电压达到5.8 V时，待机转换器可以开始开关，+12 V待机输出和初级侧偏
置电压将开始升高。偏置/辅助供电绕组的输出端由二极管D12进行整流，并由电容C20进
行滤波。偏置绕组的输出端用来在仅待机工作条件下通过电阻R16向HiperTFS-2 BP引脚
供电。当远程ON开关SW1使能U3A和U3B且命令Q1进入ON状态时，Q1和D10会从初级偏
置电源提供额外的电流。在完整的PC电源应用中，该电压用来通过J4连接器向PFC控制器
提供偏置电源。所选取的R16值可维持流入BP引脚所需的700 μA最小电流（用来抑制
HiperTFS-2高压电流源），从而降低空载功耗。电容C12连接到U6的BP引脚，为内部稳
压的5.85 V电源提供去耦。齐纳二极管VR4为Q1提供电压参考，使门极-发射极电压稳定到
12.4 V，进而使稳定的6 mA电流流入BP引脚；此外，齐纳二极管VR4还能为PFC级（如使
用）提供稳压电源。
Power Integrations, Inc.
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DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
使能(EN)引脚是待机控制器的反馈引脚。在启动之前，会对一个从EN连接到BP的电阻
R27进行检测，以便选择待机转换器多个内部限流值中的其中一个。在启动时，与EN引脚
一样，反馈(FB)引脚电阻R25用来选择三个主限流值中的一个。R27可以采用四个不同的
电阻值，用来选择待机转换器四个内部限流配置中的一个，R25可以采用三个不同的电阻
值，用来选择主转换器三个内部限流配置中的一个。此处所示的电路采用R27 (232 kΩ)来
实现650 mA的待机ILIM，采用232 kΩ的R25来实现3.1 A的主ILIM。
FB引脚为主转换器提供反馈。从FB引脚到接地电流吸收的增大将导致工作占空比的降低。
二极管D9用于在启动期间为自举充电C3和C6提供初始电源。在此期间，上管MOSFET
HS引脚被暂时拉至源极12 ms。正常工作情况下，C6的额定电压被并联调节至约12 V。有
必要始终确保电容C3上有一个最低为13 V的电压。
电阻R18、R19和R36用于将最大可用OFF时间复位电压转换为R引脚的电流，并与L引脚
电流进行比较，以计算最大允许占空比，从而避免饱和，同时确定作为峰值导通时间通量
的函数的最大允许占空因数。
线电压检测(L)引脚提供输入体电压线电压检测功能。该信息被欠压和过压检测电路同时用
于主及待机转换器。该引脚也可被拉低至源极，以同时对待机及主电源实施远程ON/OFF
控制。电阻R12、R13和R35用于将输入电压转换为L引脚的电流。
4.3
输出整流
对于待机转换器，输出整流由二极管D16提供。具有低ESR值的电容C17提供低纹波
滤波。电感L2和电容C15形成一个后级滤波器，进一步降低输出端的开关纹波和噪声。
对于主转换器，二极管D7在主导通时间期间进行整流，二极管D6是在主关断时间期间为输
出电感L1提供电流放电通路的箝位二极管。电感L1与电容C10和C24一起构成主转换器的
输出滤波器，对开关输出纹波和噪声进行滤波。
第9页（共59页）
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4.4
DER-368：使用TFS7703H设计的190 W一体机PC电源
输出反馈
对于待机转换器，电阻R34和R31形成一个反馈分压网络。电源的输出电压被分压，并馈
入误差放大器U7的输入端。U2A的阴极电压由U7内的放大器控制，以将分压器电压维持在
2.5 V ±2%。阴极电压的变化会导致流经U2A内的光耦二极管的电流发生变化，进而改变流
经U2B内的晶体管的电流。电容C19为EN引脚提供噪声抑制。当从EN引脚吸收的电流超出
EN引脚阈值电流时，下一个开关周期将被禁止；当输出电压低于反馈阈值时，会使能一个
开关周期。通过调整使能的周期数量来维持输出稳压。随负载的减轻，使能周期也随之减
少，从而降低有效的开关频率，根据负载情况减低开关损耗。因此能够在负载极轻时提供
恒定的效率，易于满足能效标准的要求。
对于主转换器，电阻R9和R24用来为U5误差放大器提供DC参考。以类似的方式，U5可以
控制用于通过从FB引脚吸入的电流来调整工作占空比的光耦器U1，主要差异是FB引脚
电流以线性方式控制主转换器的占空比，而待机转换器是采用整个周期On/Off控制。元件
C4、C8-9、R10和R21对主12 V控制环路提供补偿。元件C5与R11形成“软结束”网络，
用来防止启动时的输出过冲。
电阻R15为控制环路设置增益，电阻R10、R21和电容C4、C8和C9形成控制环路的响应，
以实现所需的环路增益交叉频率和相位裕量。电阻R38和R30提供IC U5和U7各自所要求的
偏置电流。
Power Integrations, Inc.
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DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
5 PCB布局
Figure 4 – DER-368 PCB Layout, Top View.
第11页（共59页）
Power Integrations
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DER-368：使用TFS7703H设计的190 W一体机PC电源
Figure 5 – DER-368 PCB Layout, Bottom View.
Power Integrations, Inc.
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DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
6 物料清单(BOM)
Item
Qty
Ref Des
1
1
C1
Description
Mfg Part Number
Mfg
120 μF, 450 V, Electrolytic, (22 x 30)
ESMQ451VSN121MP30S
United Chemi-con
Murata
2
1
C2
2.2 nF, 1 KV, Ceramic, SL, 0.2" L.S.
DEBB33A222KA2B
3
2
C3 C6
100 nF 50 V, Ceramic, X7R, 0603
C1608X7R1H104K
TDK
4
3
C4 C5 C8
47 nF, 50 V, Ceramic, X7R, 0805
GRM21BR71H473KA01L
Murata
5
3
C9 C18 C19
1 nF, 200 V, Ceramic, X7R, 0805
08052C102KAT2A
AVX
6
2
C10 C24
EEU-FR1C152
Panasonic
7
1
C12
10 μF, 16 V, Ceramic, X5R, 0805
GRM21BR61C106KE15L
Murata
8
1
C13
08051C471KAT2A
AVX
9
1
C15
ELXZ250ELL331MJC5S
Nippon Chemi-Con
10
1
C16
GRM219R71H334KA88D
Murata
11
1
C17
EKZE160ELL102MJ20S
Nippon Chemi-Con
12
1
C20
ELXZ350ELL331MJ16S
Nippon Chemi-Con
13
1
C21
470 pF, 100 V, Ceramic, X7R, 0805
330 μF, 25 V, Electrolytic, Low ESR, 90 mΩ,
(10 x 12.5)
330 nF, 50 V, Ceramic, X7R, 0805
1000 μF, 16 V, Electrolytic, Very Low ESR,
23 mΩ, (10 x 20)
330 μF, 35 V, Electrolytic, Low ESR, 68 mΩ,
(10 x 16)
2.2 nF, Ceramic, Y1
440LD22-R
Vishay
14
1
C22
3.3 nF, 100 V, Ceramic, X7R, Radial
15
2
D3 D4
1500 μF, 16 V, Electrolytic, Low ESR, 10 x 20)
FK18X7R2A332K
TDK
1000 V, 1 A, Rectifier, DO-41
1N4007-E3/54
Vishay
16
2
D6 D7
60 V, 30 A, Dual Schottky, TO-220AB
STPS30L60CT
ST
17
2
D8 D9
600 V, 1 A, Ultrafast Recovery, 75 ns, DO-41
UF4005-E3
Vishay
Diodes, Inc.
18
1
D10
100 V, 0.2 A, Fast Switching, 50 ns, SOD-323
BAV19WS-7-F
19
1
D12
200 V, 1 A, Ultrafast Recovery, 50 ns, DO-41
UF4003-E3
Vishay
20
1
D13
600 V, 1 A, Rectifier, DO-41
1N4005-T
Diodes, Inc.
21
1
D16
SB3100-T
Diodes, Inc.
22
1
ESIP CLIP1
NP975864
Aavid Thermalloy
23
1
37213150411
Wickman
24
2
1009-58
Bergquist
25
1
F1
HS PAD1 HS
PAD2
HS1
100 V, 3 A, Schottky, DO-201AD
Heat sink Hardware, Edge Clip 20.76 mm L x 8
mm W
3.15 A, 250V, Slow, TR5
26
1
HS2
27
1
J2
28
1
J3
HEAT SINK PAD, TO-220, Sil-Pad 1000
HEAT SINK, DER-368, Primary-
Custom
Custom
29
1
J4
HEAT SINK, DER-368, Secondary
2 Position (1 x 2) header, 5 mm (0.196) pitch,
Vertical
CONN HEADER 3POS (1x3).156 VERT TIN
(PULL PIN 2)
2 Position (1 x 2) header, 0.1 pitch, Vertical
30
1
J5
CONN TERM BLOCK 5MM 4POS
31
2
32
6
33
5
34
1
JP1 JP13
JP2 JP3 JP4
JP15 JP16 JP17
JP5 JP6 JP7
JP8 JP9 JP14
JP6
35
2
JP10
36
1
37
1715022
Phoenix Contact
26-48-1031
Molex
22-23-2021
Molex
1711042
Phoenix Contact
Wire Jumper, Non-Insulated, #22 AWG, 0.2 in
298
Alpha
Wire Jumper, Non-Insulated, #22 AWG, 0.3 in
298
Alpha
Wire Jumper, Non Insulated, #22 AWG, 0.5 in
298
Alpha
Wire Jumper, Insulated, TFE, #22 AWG, 0.5 in
C2004-12-02
Alpha
Wire Jumper, insulated, TFE, #22 AWG, 0.4 in
C2004-12-02
Alpha
JP11
Wire Jumper, insulated, TFE, #22 AWG, 0.3 in
C2004-12-02
Alpha
1
JP12
Wire Jumper, Non-insulated, #22 AWG, 1.0 in
298
Alpha
38
3
JP18 JP19 JP21
Wire Jumper, Non-insulated, #22 AWG, 0.3 in
298
Alpha
39
1
JP20
Wire Jumper, Non-insulated, #22 AWG, 0.7 in
298
Alpha
40
1
JP22
Wire Jumper, Non-insulated, #22 AWG, 0.4 in
298
Alpha
41
1
L1
第13页（共59页）
41 μH, Inductor Toroidal, Sendust
Power Integrations
电话：+1 408 414 9200 传真：+1 408 414 9201
www.powerint.com
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
2.2 μH, 6.0 A
42
1
L2
43
2
NUT1 NUT2
44
3
POSTCRKT_BRD_632_HEX1
POSTCRKT_BRD_632_HEX2
POSTCRKT_BRD_632_HEX3
45
1
Q1
46
1
R1
NPN, Small Signal BJT, GP SS, 40 V, 0.6 A,
SOT-23
2.2 Ω, 5%, 1 W, Metal Film, Fusible
47
1
R5
4.7 Ω, 5%, 1/2 W, Carbon Film
48
1
R6
100 Ω, 5%, 1/2 W, Carbon Film
CFR-50JB-100R
Yageo
49
1
R7
2.2 Ω, 5%, 1/2 W, Carbon Film
CFR-50JB-2R2
Yageo
50
1
R9
15 kΩ, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF1502V
Panasonic
51
1
R10
220 Ω, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ221V
Panasonic
52
1
R11
39 kΩ, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ393V
Panasonic
53
3
R12 R13 R19
1.33 MΩ, 1%, 1/4 W, Metal Film
MF1/4DCT52R1334F
KOA Speer
54
3
1.33 MΩ, 1%, 1/4 W, Thick Film, 1206
RC1206FR-071M33L
Yageo
55
5
1 kΩ, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ102V
Panasonic
56
1
R18 R35 R36
R14 R15 R30
R33 R38
R16
7.5 kΩ, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ752V
Panasonic
57
2
R20,R22
4.7 kΩ, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ472V
Panasonic
58
1
R21
3.3 kΩ, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ332V
Panasonic
59
1
R22
4.7 kΩ, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ472V
Panasonic
60
1
R23
619Ω, 1%, 1/4 W, Metal Film
MFR-25FBF-619R
Yageo
61
2
R25,R27
ERJ-3EKF2323V
Panasonic
62
1
R26
200 Ω, 5%, 1/4 W, Carbon Film
CFR-25JB-200R
Yageo
63
1
R28
100 Ω, 5%, 1/8 W, Thick Film, 0805
ERJ-6EGYJ101V
Panasonic
64
1
R31
4.99 kΩ, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF4991V
Panasonic
65
1
R32
10 kΩ, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ103V
Panasonic
66
1
R34
19.1 kΩ, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF1912V
Panasonic
67
1
R37
Resistor, Metal Oxide, 2.2 Ω, 1 W, 5%
RSF-100JB-2R2
Yageo
68
1
R39
4.7 kΩ, 5%, 1/4 W, Carbon Film
CFR-25JB-4K7
Yageo
69
1
120-SA
70
2
PMSSS 440 0031 PH
Wakefield
Any RoHS
Compliant Mfg.
Building Fasteners
1101M2S3CBE2
C&K Components
71
1
RTV1
SCREW1
SCREW2
SCREW3
72
1
SW1
73
1
T1
74
1
T2
75
3
U1 U2 U3
76
2
U5 U7
77
1
U6
78
1
VR3
79
1
80
3
81
2
VR4
WASHER1
WASHER2
WASHER3
WASHER6
WASHER7
RFB0807-2R2L
Coilcraft
Any RoHS
Compliant Mfg.
Nut, Hex, Kep 4-40, S ZN Cr3 plating RoHS
4CKNTZR
Post, Circuit Board, Female, Hex, 6-32, snap,
0.375L, Nylon
561-0375A
Eagle Hardware
MMBT4401LT1G
Diodes, Inc.
NFR0100002208JR500
Vishay
CFR-50JB-4R7
Yageo
232 kΩ, 1%, 1/16 W, Thick Film, 0603
Thermally conductive Silicone Grease
SCREW PHIL Flat head, undercut 4-40 X .3750
(3/8) SST
SCREW MACHINE PHIL 4-40 X 5/16 SS
SLIDE MINI SPDT PC MNT AU
Transformer, DER-368 Main, EF25, Vertical
Transformer, DER-368 Standby, EE16, Vertical
Optocoupler, 80 V, CTR 80-160%, 4-Mini Flat
Custom
PC357N1TJ00F
Sharp
LM431AIM3/NOPB
National Semi
HiperTFS-2, ESIP16/12
TFS7703H
Power Integrations
150 V, 5 W, 5%, TVS, DO204AC (DO-15)
P6KE150A
LittleFuse
MMSZ5243BT1G
ON Semi
5205820-2
Tyco
3049
Keystone
IC, REG ZENER SHUNT ADJ SOT-23
13 V, 5%, 500 mW, SOD-123
WASHER FLAT #4 Zinc, OD 0.219, ID 0.125,
Thk 0.032, Yellow Chromate Finish
Washer Nylon Shoulder #4
Power Integrations, Inc.
电话：+1 408 414 9200 传真：+1 408 414 9201
www.powerint.com
第14页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
7 设计表格
HiperTFS2_Twoswitch_Forward_041613;
INPUT
INFO
OUTPUT
Rev.1.0; Copyright
Power Integrations 2013
Hiper-TFS MAIN OUTPUT (TWO-SWITCH FORWARD STAGE)
OUTPUT VOLTAGE AND CURRENT
VMAIN
12.00
IMAIN
15.00
VOUT2
IOUT2
POST REGULATED OUTPUT
Post Regulator
NONE
UNIT
HiperTFS2_041613_Rev1-0.xls;
Two-switch Forward
Transformer Design Spreadsheet
V
A
V
A
Main output voltage
Main output current
Output2 voltage - enter zero if none
Output2 current - enter zero if none
Info
V_SOURCE
V
VOUT3
IOUT3
0
0
n_PR
1
V
A
!!!! Info. No Selection for postregulator - select 'NONE' if not using
post-regulator
Select source of input voltage for
post regulator. Enter None if Post
regulator not used.
Enter postregulator output voltage
Enter post regulator output current
Enter postregulator efficiency (Buck
only)
COUPLED-INDUCTOR (LOW POWER) DERIVED OUTPUT
VOUT4
V
IOUT4
A
Coupled-Inductor derived (low
power) output voltage (typically -12
V)
Coupled-Inductor derived (low
power) output current
Total output power (Main converter)
Peak Output power(Main converter).
If there is no peak power
requirement enter value equal to
continuous power
Continuous output power from
Standby power supply
Peak output power from Standby
section
Total system continuous output
power
POUT(Main)
180.0
W
POUT_PEAK(Main)
180.0
W
POUT(Standby)
10.3
W
POUT_PEAK(Standby)
10.0
W
POUT(System Total)
190.3
W
POUT_PEAK(System
Total)
190.0
W
Total system peak output power
V
DC bias voltage from main
transformer aux winding
VBIAS
17.00
INPUT VOLTAGE AND UV/OV
CIN
120
uF
20
120
0.55
0.67
0.25
ms
uF
ohms
A
W
VMIN
300.0
V
VNOM
VMAX
RR
380.0
420.0
3.92
V
V
M-ohm
RL
3.92
M-ohm
T_HOLDUP
CIN
CIN_ESR
IRMS_CIN
PLOSS_CIN
第15页（共59页）
120.00
120.00
Input Capacitance. To increase
CMIN, increase T_HOLDUP
Holdup time
Select Bulk Capacitor
Bulk capacitor ESR
RMS current through bulk capacitor
Bulk capacitor ESR losses
Minimum input voltage to guarantee
output regulation
Nominal input voltage
Maximum DC input voltage
Minimum undervoltage On-Off
threshold
Power Integrations
电话：+1 408 414 9200 传真：+1 408 414 9201
www.powerint.com
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
UV / OV / UVOV
VUV OFF (min)
181.8
V
VUV ON (min)
295.5
V
VOV ON (min)
526.7
V
VOV OFF (min)
526.7
V
VUV OFF (max)
VUV ON (max)
ENTER DEVICE VARIABLES
Device
225.0
326.9
V
V
Select Frequency mode
TFS7703
TFS7703
f
f
ILIMIT_MIN
ILIMIT_TYP
ILIMIT_MAX
3.01
3.24
3.47
A
A
A
fSMIN
124000
Hz
fS
132000
Hz
fSMAX
140000
Hz
KI
1.0
1.0
R(FB)
ILIMIT SELECT
RDS(ON)
232.0
3.01
5.00
k-ohms
A
ohms
DVNOM_GOAL
0.45
VDS
5.07
V
Main MOSFET losses
RDSON_LOWER
RDSON_UPPER
PCOND_LOWER
3.60
1.40
2.6
ohm
ohm
W
PCOND_UPPER
1.0
W
COSS_LOWER
COSS_UPPER
35
110
pF
pF
V_Coss upper FET
150
V
P_Coss lower FET
P_Coss upper FET
lower FET crossoever loss
0.12
0.16
0.72
W
W
W
TOTAL_MOSFET_LOSS
6.92
Minimum undervoltage Off-On
threshold (turn-on)
Minimum overvoltage Off-On
threshold
Minimum overvoltage On-Off
threshold (turn-off)
R pin resistor
Line Sense resistor value (L-pin) goal seek (VUV OFF) for std 1%
resistor series
Selected HiperTFS device
Select Frequency mode. "H"
indicates 66 kHz selection, "F"
indicates 132 kHz selection
Device current limit (Minimum)
Device current limit (Typical)
Device current limit (Maximum)
Device switching frequency
(Minimum)
Device switching frequency (Typical)
Device switching frequency
(Maximum)
Select Current limit factor (KI=1.0 for
default ILIMIT, or select KI=0.9 or
KI=0.7)
Feedback Pin Resistor value
Selected current limit
Rds(on) at 100'C
Target duty cycle at nominal input
voltage (VNOM)
HiperTFS average on-state Drain to
Source Voltage
RDSON for low side MOSFET
RDSON for high side MOSFET
Conduction losses in lower MOSFET
Conduction losses in upper
MOSFET
COSS for low side MOSFET
COSS for high side MOSFET
Voltage across upper MOSFET
during turn off
Switching loss in upper MOSFET
Switching loss in lower MOSFET
Crossover loss in lower MOSFET
Total loss in MOSFET (upper +
lower)
Clamp Section
Clamp Selection
CLAMP TO
RAIL
VCLAMP
150.00
V
VDSOP
570.00
V
0.4
V
0.5
V
Select either "CLAMP TO RAIL"
(default) or "CLAMP TO GND"
Asymmetric Clamp Voltage
Maximum Hiper-TFS Drain voltage
(at VOVOFF_MAX)
DIODE Vf SELECTION
VDMAIN
0.40
VDOUT2
Power Integrations, Inc.
电话：+1 408 414 9200 传真：+1 408 414 9201
www.powerint.com
Main output diodes forward voltage
drop
Secondary output diodes forward
voltage drop
第16页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
VDOUT3
0.5
V
VDB
TRANSFORMER CORE SELECTION
Core Type
Auto
AE
LE
AL
BW
B_HT
B_WA
0.7
V
EF25
0.518
5.78
2000
15.6
4.60
0.72
cm^2
cm
nH/T^2
mm
mm
cm^2
4.5
mm
0.002
mm
20
mH
9
mH
173.04
kHz
90
pF
M
LG_MAX
LMAG_MAX
LMAG
9.4
FRES_TRF
C_TRF
L
3.00
NMAIN
NS2
5.0
5.0
0.0
NBIAS
0
0
VOUT2 ACTUAL
0.0
V
VBIAS_ACTUAL
-0.7
V
TRANSFORMER DESIGN PARAMETERS
NP
64
BM_MAX
2548
Gauss
BM PK-PK
3861
Gauss
BP_MAX
3229
Gauss
BP PK-PK
4892
Gauss
IMAG
0.136
A
OD_P
0.31
mm
29
AWG
AWG_P
TRANSFORMER LOSSES AND FIT ESTIMATE
Core loss
Core material
Auto
BAC_pp
core_loss_multiplier
f_coeff
BAC_coeff
specific core loss
core volume
core loss
第17页（共59页）
12.4
PC95
3627
2.04E-03
1.80
2.56
995.50
3.02
3.01
gauss
mW/cc
cm^3
W
3rd output diodes forward voltage
drop
Bias diode forward voltage drop
Selected core type
Core Effective Cross Sectional Area
Core Effective Path Length
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
Height of bobbin (to calculate fit)
Bobbin Winding area
Bobbin safety margin tape width (2 *
M = Total Margin)
Maximum zero gap tolerance,
default 2um
Maximum magnetizing inductance of
transformer. Do not exceed this
value
Actual magnetizing inductance
(measured) of transformer
Measured Primary winding self
resonant frequency
Estimated primary winding
capacitance
Transformer primary layers (split
primary recommended)
Main rounded turns
2nd output number of turns
VBias rounded turns (forward
bias winding)
Approximate Output2 voltage of with
NS2 = 0 turns (AC stacked
secondary)
Approximate Forward Bias Winding
Voltage at VMIN with NB = 0 turns
Primary rounded turns
Max positive operating flux density at
minimum switching frequency
Max peak-peak operating flux
density at minimum switching
frequency
Max positive flux density at Vmax
(limited by DVMAX clamp)
Max peak-peak flux density at Vmax
(limited by DVMAX clamp)
Peak magnetizing current at
minimum input voltage
Primary wire outer diameter
Primary Wire Gauge (rounded to
maximum AWG value)
Select core material
Peak to peak flux density
Core Loss constant
Frequency co-efficient
AC flux density co-efficient
Core loss per unit volume
Volume of core
Core loss
Power Integrations
电话：+1 408 414 9200 传真：+1 408 414 9201
www.powerint.com
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
PRI WINDING FIT AND LOSSES
OD_PRI
0.45
mm
FILAR_PRI
1.00
strands
5.28
465.19
0.34
14
cm
milli-ohm
W
%
12
5.0
11.62
FOIL
0.125
V
turns
A
foil/wire
mm
FILAR_SEC1
N/A
strands
SEC1_WIDTH
18
mm
SEC1_MLT
DCR_SEC1
5.28
2.59
cm
milli-ohms
PCOND_SEC1
0.35
W
16
%
0
0.0
0.00
FOIL
0.125
V
turns
A
foil/wire
mm
FILAR_SEC2
N/A
strands
SEC2_WIDTH
18
mm
SEC2_MLT
DCR_SEC2
5.28
0.00
cm
milli-ohms
PCOND_SEC2
0.00
W
0
%
Number of turns
RMS current through winding
Select FOIL or WIRE for winding
Wire diameter or Foil thickness
Number of parallel strands (wire
selection only)
Foil Width (Applicable if
FOIL winiding used)
Mean length per turn
DC resistance of secondary winding
Conduction loss in
secondary winding
Fill factor (secondary 1 only)
30
0.7
3.0
3.7
%
W
W
W
Total transformer fill factor
Total copper losses in transformer
Total core losses in transformer
Total losses in transformer
MLT_PRI
DCR_PRI
PCOND_PRI
FILL_PRI
SEC WINDING 1 (lower winding when AC stacked)
VOUT
NS1
IRMS_SEC1
Foil/Wire
FOIL
OD/Thickness
FILL_SEC1
SEC WINDING 2 (upper winding AC stacked)
VOUT
NS2
IRMS_SEC2
Foil/Wire
FOIL
OD/Thickness
FILL_SEC2
Total main transformer
FILL_TOTAL
TOTAL_CU_LOSS
TOTAL_CORE_LOSS
TOTAL_TRF_LOSS
DUTY CYCLE VALUES (REGULATION)
DVMIN
0.57
DVNOM
0.45
DVMAX
0.41
DOVOFF MIN
0.32
Primary winding diameter
Number of parallel strands of wire
(primary)
Mean length per turn
DC resistance of primary winding
Conduction loss in primary winding
Fill factor (primary only)
Number of turns
RMS current through winding
Select FOIL or WIRE for winding
Wire diameter or Foil thickness
Number of parallel strands (wire
selection only)
Foil Width (Applicable if
FOIL winiding used)
Mean length per turn
DC resistance of secondary winding
Conduction loss in
secondary winding
Fill factor (secondary 1 only)
Duty cycle at minimum DC input
voltage
Duty cycle at nominal DC input
voltage
Duty cycle at maximum DC input
voltage
Duty cycle at overvoltage DC input
voltage(DOVOFF_MIN)
MAXIMUM DUTY CYCLE VALUES
DMAX_UVOFF_MIN
0.65
DMAX_VMIN
DMAX_VNOM
DMAX_VMAX
0.60
0.56
0.51
Power Integrations, Inc.
电话：+1 408 414 9200 传真：+1 408 414 9201
www.powerint.com
Max duty cycle clamp at
VUVOFF_MIN
Max duty clamp cycle at VMIN
Max duty clamp cycle at VNOM
Max duty clamp cycle at VMAX
第18页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
DMAX_OVOFFMIN
12-Nov-13
Max duty clamp cycle at
VOVOFF_MAX
0.41
CURRENT WAVESHAPE PARAMETERS
IP
1.49
A
IP_PEAK
1.49
A
IPRMS(NOM)
0.85
A
Maximum peak primary current at
maximum DC input voltage
Peak primary current at Peak Output
Power and max DC input voltage
Nominal primary RMS current at
nominal DC input voltage
OUTPUT INDUCTOR OUTPUT PARAMETERS
KDI_ACTUAL
Core Type
Core
AE
LE
AL
BW
VE
MUR
H
0.31
Kool Mu 125u
77350(O.D)=24.3
Kool Mu 125u
77350(O.D)=24.3
38.80
58.80
105.00
43.26
2280.00
Powder cores (Sendust and Powdered Iron) Cores
125.00
55.49
mm^2
mm
nH/T^2
mm
mm^3
AT/cm
MUR_RATIO
0.29
LMAIN_ACTUAL
12.1
uH
LMAIN_0bias
42.00
uH
LOUT2
BM_IND
BAC_IND
Turns
INDUCTOR TURNS
MULTIPLIER
NMAIN_INDUCTOR
NOUT2_INDUCTOR
NOUT4_INDUCTOR
0.00
uH
2534.69
388.82
Gauss
Gauss
Relative permeability of material
Magnetic field strength
Percent of permeability as compared
to permiability at H = 0 AT/cm
Estimated inductance of main
output at full load
Estimated inductance of main
output with 0 DC bias
Estimated inductance of auxiliary
output at full load
DC component of flux density
AC component of flux density
Multiplier factor between main
number of turns in transformer and
inductor (default value = 3)
Main output inductor number of turns
Output 2 inductor number of turns
Bias output inductor number of turns
(for bias or control circuit VDD
supply)
3.00
20
Current ripple factor of combined
Main and Output2 outputs
Select core type
Coupled Inductor - Core size
Core Effective Cross Sectional Area
Core Effective Path Length
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
Volume of core
20.00
0.00
N/A
Ferrite Cores
LMAIN_ACTUAL
N/A
uH
LOUT2
LG
Target BM
N/A
N/A
N/A
uH
mm
Gauss
BM_IND
N/A
Gauss
BAC_IND
Turns
NMAIN_INDUCTOR
NAUX_INDUCTOR
N_BIAS
Wire Parameters
N/A
Gauss
Total number of layers
1.03
IRMS_MAIN
15.02
A
IRMS_AUX
0.00
A
第19页（共59页）
N/A
N/A
N/A
Estimated inductance of main
output
Estimated inductance of aux output
Gap length of inductor cores
Target maximum flux density
Estimated maximum operating flux
density
AC flux density
Main output inductor number of turns
Aux output inductor number of turns
Aux output inductor number of turns
Total number of layers for chosen
toroid
RMS current through main
inductor windings
RMS current through aux winding
Power Integrations
电话：+1 408 414 9200 传真：+1 408 414 9201
www.powerint.com
12-Nov-13
AWG_MAIN
DER-368：使用TFS7703H设计的190 W一体机PC电源
18
18.00
AWG
OD_MAIN
1.09
mm
FILAR_MAIN
2.00
RDC_MAIN
6.74
AC Resistance Ratio
(Main)
3.78
mohm
CMA_MAIN
216.57
CMA
J_MAIN
15.96
A/mm^2
AWG_AUX
0.00
AWG
OD_MAIN
N/A
mm
FILAR_AUX
2.00
RDC_AUX
0.00
AC Resistance Ratio
(Aux)
0.00
CMA_AUX
mohm
0.00
CMA
J_AUX
Estimated Power Loss
PCOPPER_MAIN
PCOPPER_AUX
PCORE
PTOTAL_IND
SECONDARY OUTPUT PARAMETERS
0.00
A/mm^2
1.52
0.00
0.43
1.95
W
W
W
W
ISFWDRMS
11.62
A
ISFWD2RMS
0.00
A
ISCATCHRMS
12.83
A
ISCATCH2RMS
0.00
A
IDAVMAINF
8.59
A
IDAVMAINC
8.90
A
IDAVOUT2F
0.00
A
IDAVOUT2C
0.00
A
IRMSMAIN
1.33
A
IRMSOUT2
0.00
A
6
0
W
W
44.5
V
Info
PD_LOSS_MAIN
PD_LOSS_OUT2
Main inductor winding wire gauge
Main winding wire gauge outer
diameter
Number of parallel strands for main
output
Resistance of wire for main
inductor winding
Ratio of total resistance (AC + DC)
to the DC resistance (using Dowell
curves)
Cir mils per amp for main
inductor winding
Current density in main
inductor winding
Aux winding wire gauge
Auxiliary winding wire gauge outer
diameter
Number of parallel strands for aux
output
Resistance of wire for aux
inductor winding
Ratio of total resistance (AC + DC)
to the DC resistance (using Dowell
curves)
!!! Info. Low CMA may cause
overheating. Verify acceptable
temperature rise
Current density in auxiliary winding
Copper loss in main inductor winding
Copper loss in aux inductor windings
Total core loss
Total losses in output choke
Max. fwd sec. RMS current
(at DVNOM)
Max. fwd sec. RMS current
(at DVNOM)
Max. catch sec. RMS current
(at DVNOM)
Max. catch sec. RMS current
(at DVNOM)
Maximum average current, Main
rectifier (single device rating)
Maximum average current, Main
rectifier (single device rating)
Maximum average current, Main
rectifier (single device rating)
Maximum average current, Main
rectifier (single device rating)
Maximum RMS current, Main output
capacitor
Maximum RMS current, Out2 output
capacitor
main diode loss
output 2 diode loss
% Derating
VPIVMAINF
100%
Power Integrations, Inc.
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Main Forward Diode peak-inverse
voltage (at VDSOP)
第20页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
VPIVMAINC
100%
32.8
V
VPIVOUT2F
100%
0.0
V
VPIVOUT2C
100%
0.0
V
VPIVB
100%
0.0
V
Hiper-TFS STANDBY SECTION (FLYBACK STAGE)
ENTER APPLICATION VARIABLES
VACMIN
85
VACMAX
265
fL
50
V
V
Hz
VO_SB
12.00
V
IO_SB
0.83
A
IO_SB_PK
POUT_SB
0.83
9.96
W
POUT_SB_TOTAL
10.28
W
POUT_SB_PK
9.96
W
n
0.80
Z
0.50
tC
3.00
ms
Main Catch Diode peak-inverse
voltage (at VOVOFF_MAX)
Output2 Forward Diode peak-inverse
voltage (at VDSOP)
Output2 Catch Diode peak-inverse
voltage (at VOVOFF_MAX)
Bias output rectifier peak-inverse
voltage (at VDSOP)
Minimum AC Input Voltage
Maximum AC Input Voltage
AC Mains Frequency
Output Voltage (at continuous
power)
Power Supply Output Current
(corresponding to peak power)
Peak output current
Continuous Output Power
Total Standby power (Includes
Bias winding power)
Peak Standby Output Power
Efficiency Estimate at output
terminals. Under 0.7 if no better data
available
Z Factor. Ratio of secondary side
losses to the total losses in the
power supply. Use 0.5 if no better
data available
Bridge Rectifier Conduction Time
Estimate
ENTER Hiper-TFS STANDBY VARIABLES
Select Current Limit
STD
ILIM_MIN
ILIM_TYP
ILIM_MAX
R(EN)
Standard Current
Limit
0.605
0.650
0.696
232.0
A
A
A
k-ohms
124000
Hz
50.19
A^2kHz
100
V
VDS
10
V
VD_SB
0.7
V
KP
1.55
KP_TRANSIENT
1.27
ENTER BIAS WINDING VARIABLES
VB
IB
PB
16.00
20.00
0.32
fSmin
I^2fmin
VOR
第21页（共59页）
100.00
V
mA
W
Enter "LOW" for low current limit,
"RED" for reduced current limit
(sealed adapters), "STD" for
standard current limit or "INC" for
increased current limit (peak or
higher power applications)
Minimum Current Limit
Typical Current Limit
Maximum Current Limit
Enable pin resistor
Minimum Device Switching
Frequency
I^2f (product of current limit squared
and frequency is trimmed for tighter
tolerance)
Reflected Output Voltage (VOR <
135 V Recommended)
Hiper-TFS Standby On State Drain
to Source Voltage
Output Winding Diode Forward
Voltage Drop
Ripple to Peak Current Ratio (KP <
6)
Transient Ripple to Peak Current
Ratio. Ensure KP_TRANSIENT >
0.25
Bias Winding Voltage
Bias winding Load current
Bias winding power
Power Integrations
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DER-368：使用TFS7703H设计的190 W一体机PC电源
VDB
0.70
V
NB
15.00
VZOV
22.00
V
3.92
M-Ohms
Bias Winding Diode Forward
Voltage Drop
Bias Winding Number of Turns
Overvoltage Protection zener diode
voltage.
UVLO VARIABLES
RLS
V_UV_ACTUAL
100
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type
EE16
EE16
AE
0.192
LE
3.5
AL
1140
BW
8.6
M
0
L
3.00
NS_SB
11
DC INPUT VOLTAGE PARAMETERS
VMIN_SB
VMAX_SB
CURRENT WAVEFORM SHAPE PARAMETERS
3
11
DMAX_SB
114.01
374.77
V
cm^2
cm
nH/T^2
mm
mm
Minimum DC Input Voltage
Maximum DC Input Voltage
Duty Ratio at full load, minimum
primary inductance and minimum
input voltage
Average Primary Current
Minimum Peak Primary Current
Primary Ripple Current
Primary RMS Current
IAVG
IP_SB
IR_SB
IRMS_SB
TRANSFORMER PRIMARY DESIGN PARAMETERS
0.12
0.6045
0.6045
0.24
A
A
A
A
LP_SB
491.12
uH
10
87
65
%
nH/T^2
BM
2054
Gauss
BAC
1027
Gauss
ur
1654
LG
BWE
0.35
25.8
mm
mm
OD
0.298
mm
INS
0.05
mm
DIA
0.246
mm
AWG
31
AWG
CM
81
Cmils
CMA
334
Cmils/Amp
TRANSFORMER SECONDARY DESIGN PARAMETERS
Lumped parameters
ISP
4.76
A
Power Integrations, Inc.
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Enter Transformer Core
Core Effective Cross Sectional Area
Core Effective Path Length
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
Safety Margin Width (Half the
Primary to Secondary
Creepage Distance)
Number of Primary Layers
Number of Secondary Turns
V
V
0.36
LP_TOLERANCE
NP_SB
ALG
Line sense resistor (from Main
converter section)
Typical DC start-up voltage
Typical Primary Inductance. +/- 10%
to ensure a minimum primary
inductance of 446 uH
Primary inductance tolerance
Primary Winding Number of Turns
Gapped Core Effective Inductance
Maximum Operating Flux Density,
BM<3000 is recommended
AC Flux Density for Core Loss
Curves (0.5 X Peak to Peak)
Relative Permeability of Ungapped
Core
Gap Length (Lg > 0.1 mm)
Effective Bobbin Width
Maximum Primary Wire Diameter
including insulation
Estimated Total Insulation Thickness
(= 2 * film thickness)
Bare conductor diameter
Primary Wire Gauge (Rounded to
next smaller standard AWG value)
Bare conductor effective area in
circular mils
Primary Winding Current Capacity
(200 < CMA < 500)
Peak Secondary Current
第22页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
ISRMS
2.03
A
Secondary RMS Current
Output Capacitor RMS Ripple
Current
Secondary Bare Conductor minimum
circular mils
Secondary Wire Gauge (Rounded
up to next larger standard AWG
value)
IRIPPLE
1.85
A
CMS
406
Cmils
AWGS
24
AWG
VDRAIN
605
V
PIVS
60
V
0.27
W
Estimated PCB trace losses
6.9
3.69
6.00
0.25
1.95
W
W
W
W
W
0.27
W
HiperTFS losses
Main transformer losses
Output diode losses
Bulk capacitor ESR losses
Output choke losses
Other losses (includes PCB traces,
clamp loss, standby loss, magamp
loss etc.)
Total system efficiency
VOLTAGE STRESS PARAMETERS
Other Losses
PCB trace losses
Forward DC-DC System efficiency
TOTAL_MOSFET_LOSS
TOTAL_TRF_LOSS
Output diode losses
PLOSS_CIN
PTOTAL_IND
Other Losses
Efficiency
90.4%
Maximum Drain Voltage Estimate
(Assumes 20% zener clamp
tolerance and an additional 10%
temperature tolerance)
Output Rectifier Maximum Peak
Inverse Voltage
Note: Main transformer outer limbs were gapped by using a 3M 74 tape in order to avoid the pulse skipping
issue. Magnetizing inductance was brought down to 3.4 mH from 9 mH. Refer to main transformer
specification section for details.
第23页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
8 主变压器(T1)规格
8.1
电气原理图
Figure 6 – Main 12 V Transformer (T1) Electrical Diagram.
8.2
电气规格
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage
Inductance
8.3
1 second, 60 Hz, from pins 4-6 to pins 7-12.
Pins 4-6, all other windings open, measured at 100 kHz,
0.4 VRMS.
Pins 4-6, all other windings open.
Pins 4-6, with pins 7-12 shorted, measured at 100 kHz,
0.4 VRMS.
3000 VAC
3.4 mH ±10%
450 kHz (Min.)
16 μH max
材料
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
Description
Core Pair: EF25, TDK PC44 material or equivalent, ungapped.
Bobbin: EF25-Vertical, 12 pins (6/6). Taiwan Shulin Enterprise TF-2554.
Tape: Polyester Film, 3M 1350F-1 or equivalent, 14.9 mm wide.
Tape: Polyester Film, 3M 1350F-1 or equivalent, 22 mm wide.
Copper Foil, 0.005” thick, 0.7” wide.
Tinned Solid Copper Bus Wire, #20 AWG.
Triple Insulated Wire, Furukawa Tex-E or equivalent, 26 #AWG.
Tape: Polyester Film, 3M 74, 0.5 mil thick, or equivalent. Cut into size: 7.0 mm x 3.5 mm.
Varnish: Dolph BC-359, or equivalent.
Power Integrations, Inc.
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第24页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
8.4
12-Nov-13
结构图
Figure 7 – Main Transformer Build Diagram.
Put tape item [8] firmly and evenly on both side legs on 1
core half
Figure 8 – Making Core Gap.
第25页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
Figure 9 – Transformer Output Foil Construction Drawing.
Power Integrations, Inc.
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第26页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
8.5
12-Nov-13
制作说明
Assembly Step
Primary
(WDG1)
Insulation
Secondary
(WDG2)
Insulation
Primary
(WDG3)
Insulation
Final Assembly
Winding Instructions
Starting at pin 2, wind 41T of triple insulated wire (Item [7] in two layers. Finish at
pin 6.
Insulate using 2 layers of tape (item [3]).
Using Items [4], [5], and [6], construct a 250 mm long cuffed foil assembly per
Figure 8. Starting at pins 10, 11, and 12, wind 5 turns of foil, finishing at pins 7, 8,
and 9.
Apply 2 layers of tape (item [3]) for insulation.
Starting at pin 4, wind 22 turns of triple insulated wire (item [7]) in a single layer,
finishing at pin 2.
Apply three layers of tape (item [3]) for finish wrap.
Use 2 pieces of tape item [8] press firmly, evenly on both side legs on 1 core half
to create 0.5 mil core gap. (see Figure 8 above).
Note: If without transformer gapping, in this design it has been found there is a high-side
driver pulse skipping issue. In this design, it happens at >400 VDC input and <3.5 A load
on main 12 V channel, when there is a snubber circuit at the main transformer secondary
output. Pulse skipping is avoided by gapping outer limbs of the transformer with the help
of 0.5 mil thick tape.
Pulse skipping is caused due to drop in VDDH pin voltage. When there is not enough
magnetizing current, high side source voltage doesn’t reach ground during core reset
period and bootstrap diode cannot charge high side VDDH bootstrap capacitor. With
insufficient voltage on the VDDH pin, high side driver could skip pulses.
Pulse skipping is not necessarily present in all the designs. Depending on the load levels
and snubber values, the conditions to have pulse skipping issue will vary as well.
Pulse skipping can be avoided by doing one of following options:
1. By providing gap on center limb of the transformer in order to reduce the
magnetizing inductance (as used in this design).
2. By adding a high side bias winding.
3. Remove the secondary snubber and use high voltage diodes on the secondary.
Option 1 may result in slight efficiency degradation, especially on lighter load. Option 2
should not affect efficiency but it adds transformer cost. In option 3, if a snubber is not
used, the output diode needs to have a higher voltage rating. This results in lower
efficiency at full load.
第27页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
9 输出电感(L1)规格
9.1
电气原理图
Figure 10 – Output Inductor Schematic Diagram.
9.2
电气规格
Inductance
9.3
Pins FL1-FL2, all other windings open, measured at 100 kHz, 0.4 VRMS.
41 μH ±15%
材料
Item
[1]
[2]
Description
Sendust Toroidal Core, 125µ: Magnetics, Inc. 77350-A7 or equivalent.
Magnet wire: #18 AWG Solderable Double Coated.
Power Integrations, Inc.
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第28页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
10 待机电源变压器(T2)规格
10.1 电气原理图
Figure 11 – Standby Transformer Electrical Diagram.
10.2 电气规格
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage Inductance
1 second, 60 Hz, from pins 1-5 to pins 5-10.
Pins 3-5, all other windings open, measured at
100 kHz, 0.4 VRMS.
Pins 3-5, all other windings open.
Pins 3-5, with pins 6, 7, 9, 10 shorted, measured
at 100 kHz, 0.4 VRMS.
3000 VAC
491 μH ±10%
1 MHz (Min.)
13 μH (Max)
10.3 材料
Item
[1]
[2]
[3]
[4]
[5]
[6]
Description
2
Core: EE16, TDK PC44 material or equivalent, gapped for ALG 96 nH/T .
Bobbin: EE16, Vertical, 10 pins (5/5). Yh Hwa YW-527-00B.
Tape: 3M 1350 F1 or equivalent, 10.8 mm wide.
Magnet wire: #31 AWG, double coated.
Triple Insulated Wire: Furukawa Tex-E or equivalent, #24 AWG.
Varnish: Dolph BC-359, or equivalent.
第29页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
10.4 结构图
Figure 12 – Build Diagram for Standby Transformer.
10.5 制作说明
Assembly Step
Primary (WDG1)
Insulation
Secondary
(WDG2)
Insulation
Primary Bias
(WDG3)
Insulation
Primary (WDG4)
Insulation
Final Assembly
Winding Instructions
Starting at pin 5, wind 60 T of wire (Item [4] in two layers. Finish at pin 4.
Insulate using 2 layers of tape (item [3]).
Starting at pins 9 and 10, wind 11 turns of triple insulated wire (item [5]), finishing at
pins 6 and 7.
Apply 2 layers of tape (item [3]) for insulation.
Starting at pin 2, wind 15 bifilar turns of wire (item [4]) in a single layer, finishing at
pin 1.
Apply one turn of tape (item [3]) for insulation.
Starting at pin 4, wind 27 turns of triple insulated wire (item [8]), finishing at pin 3.
Apply three layers of tape (item [3]) for finish wrap.
Grind core gap to specified inductance coefficient. Assemble bobbin and core
halves, secure cores. Dip varnish (item [6]).
Power Integrations, Inc.
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第30页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
11 散热片组件
11.1 初级金属散热片
Figure 13 – Primary Heat Sink Sheet Metal Drawing.
第31页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
11.2 完成的初级散热片
Figure 14 – Completed Primary Heat Sink.
Power Integrations, Inc.
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第32页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
11.3 初级散热片装配
Figure 15 – Primary Heat Sink Assembly.
第33页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
11.4 次级金属散热片
Figure 16 – Secondary Heat Sink Sheet Metal Drawing.
Power Integrations, Inc.
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第34页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
11.5 完成的次级散热片
Figure 17 – Completed Secondary Heat Sink.
第35页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
11.6 次级散热片装配
Figure 18 – Secondary Heat Sink Assembly.
Power Integrations, Inc.
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第36页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
12 性能测量
12.1 效率
100
95
Efficiency (%)
90
85
80
75
70
65
60
0
25
50
75
100
125
150
175
Output Power (W)
Figure 19 – Efficiency vs. Output load Percentage, Main + Standby Outputs.
第37页（共59页）
Power Integrations
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200
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
100
95
Efficiency (%)
90
85
80
75
70
65
60
0
25
50
75
100
125
150
175
200
Output Power (W)
Figure 20 – Main 12 V Output Efficiency vs. Output Power, 380 VDC Input, Standby Output Unloaded.
Power Integrations, Inc.
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第38页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
90
126 V Input
380 V Input
85
Efficiency (%)
80
75
70
65
60
0
2
4
6
8
10
Output Power (W)
Figure 21 – Standby Efficiency vs. Load.
第39页（共59页）
Power Integrations
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12
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
89
87
Efficiency (%)
85
83
81
79
77
75
100
150
200
250
300
350
400
Input Voltage (VDC)
Figure 22 – Standby Efficiency vs. Input Voltage, 100% Load.
Power Integrations, Inc.
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第40页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
12.2 待机空载输入功率
0.3
Input Power (W)
0.25
0.2
0.15
0.1
0.05
0
100
150
200
250
300
350
Input Voltage (VDC)
Figure 23 – Standby No-Load Input Power vs. Input Voltage.
第41页（共59页）
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400
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
12.3 调整
105
104
103
Regulation (%)
102
101
100
99
98
97
96
95
0
10
20
30
40
50
60
70
80
90
100
Percentage of Maximum Load (%)
Figure 24 – Standby Supply Load Regulation, 380 VDC Input.
Power Integrations, Inc.
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第42页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
105
104
103
Regulation (%)
102
101
100
99
98
97
96
95
0
10
20
30
40
50
60
70
80
90
Percentage of Maximum Load (%)
Figure 25 – Main Output Load Regulation, 380 VDC Input.
第43页（共59页）
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100
12-Nov-13
DER-368：使用TFS7703H设计的190 W一体机PC电源
12.4 波形
Figure 26 – Main Output Drain Voltage and Current,
Full Load, 380 VDC Input.
Upper: IDRAIN, 0.5 A / div.
Lower: VDRAIN, 200 V, 2 μs / div.
Figure 27 – Standby Output Drain Voltage and
Current, Full Load, 126 VDC (90 VAC
equiv.) Input.
Upper: IDRAIN, 0.5 A / div.
Lower: VDRAIN, 100 V, 10 μs / div.
Figure 28 – Standby Output Drain Voltage and
Current, Full load, 380 VDC Input.
Upper: IDRAIN, 0.5 A / div.
Lower: VDRAIN, 200 V, 10 μs / div.
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第44页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
12-Nov-13
12.5 主输出二极管峰值反向电压
Figure 29 – Main Output Catch Diode (D6) Reverse
Voltage, 380 VDC Input, Full Load,
20 V, 1 μs / div.
Figure 30 – Main Output Catch Diode (D6) Reverse
Voltage, 420 VDC Input, Full Load,
20 V, 1 μs / div.
Figure 31 – Main Output Forward Diode (D7)
Reverse Voltage, 380 VDC Input, Full
Load, 20 V, 1 μs / div. PRV = 2.08 div.
X 20 V / div. = 41.6 V
Figure 32 – Main Output Forward Diode (D7)
Reverse Voltage, 420 VDC Input, Full
Load, 20 V, 1 μs / div. PRV = 2.2 div. X
20 V / div. = 44 V
第45页（共59页）
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Figure 33 – Standby Output Rectifier Diode (D16)
Reverse Voltage, 380 VDC Input, Full
Load, 50 V, 2 μs / div.
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Figure 34 – Standby Output Rectifier Diode (D16)
Reverse Voltage, 420 VDC Input, Full
Load, 50 V, 2 μs / div.
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12.6 启动和维持
Figure 35 – 12 V Main Output Start-up, Full Load,
380 VDC Input, Resistive Load, 5 V,
2 ms / div.
Figure 37 – 12 V Aux Output Start-up, 126 VDC
Input, Zero Load, 5 V, 10 ms / div.
第47页（共59页）
Figure 36 – 12 V Main Output Start-up, 3% Load,
380 VDC Input, Resistive Load, 5 V,
2 ms / div.
Figure 38 – 12 V Aux Output Start-up, 126 VDC
Input, Full Load, 5 V, 10 ms / div.
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DER-368：使用TFS7703H设计的190 W一体机PC电源
Figure 39 – 12 V Aux Output Start-up, 380 VDC
Input, Zero Load, 5 V, 10 ms / div.
Figure 40 – 12 V Aux Output Start-up, 380 VDC
Input, Full Load, 5 V, 10 ms / div.
Figure 41 – Main Output Hold-up Time, Full Load.
Upper: VOUT, 5 V / div.
Lower: B+ Voltage, 200 V, 10 ms / div.
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12.7 纹波
12.7.1 纹波测量方法
For DC output ripple measurements, a modified oscilloscope test probe must be utilized
in order to reduce spurious signals due to noise pickup. Details of the probe modification
are provided in the figures below.
The 4987BA probe adapter is affixed with two capacitors tied in parallel across the probe
tip. The capacitors include one (1) 0.1 μF / 50 V ceramic type and one (1) 1.0 μF / 50 V
aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper
polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 42 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)
Figure 43 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter.
(Modified with Wires for Ripple Measurement, and Two Parallel Decoupling Capacitors
added)
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DER-368：使用TFS7703H设计的190 W一体机PC电源
12.7.2 纹波测量结果
Figure 44 – Ripple, 12 V Main Output, Full Load,
380 VDC Input. 50 mV, 1 ms / div.
Figure 45 – Ripple, 12 V Standby Output, Full Load,
126 VDC Input 50 mV, 1 ms / div.
Figure 46 – Ripple, 12 V Standby Output, Full Load,
380 VDC Input 50 mV, 1 ms / div.
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12.8 瞬态响应
In Figures 47-48, and 51-52, data was collected with the oscilloscope set to averaging
mode, so that events non-synchronous with the load step (such as high frequency output
ripple, are average out, leaving a clear view of the response to the step load change.
Figure 47 – 12 V Main Output Load Transient
Response, 75% - 100% - 75% Load
Step, 380 VDC Input.
Upper: IOUT, 5 A / div.
Lower: VOUT, 20 mV, 500 μs / div.
Figure 48 – 12 V Main Output Load Transient
Response, 100% – 180% – 100%
Load Step, 380 VDC Input.
Upper: IOUT, 10 A / div.
Lower: VOUT, 20 mV, 500 μs / div.
Figure 49 – 12 V Main Output Load Transient
Response, 3% - 100% - Load Step,
380 VDC Input.
Upper: IOUT, 5 A / div.
Lower: VOUT, 100 mV, 500 μs / div.
Figure 50 – 12 V Main Output Load Transient
Response, 100% - 3% Load Step,
380 VDC Input.
Upper: IOUT, 5 A / div.
Lower: VOUT, 100 mV, 2 ms / div.
第51页（共59页）
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Figure 51 – 12 V Standby Output Load Transient
Response, 75% - 100% - 75% Load
Step, 126 VDC Input.
Upper: IOUT, 0.5 A / div.
Lower: VOUT, 20 mV, 500 μs / div.
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Figure 52 – 12 V Standby Output Load Transient
Response, 75% - 100% - 75% Load
Step, 380 VDC Input.
Upper: IOUT, 0.5 A / div.
Lower: VOUT, 20 mV, 500 μs / div.
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13 热测试
The test setup for evaluating component temperature with forced air cooling is shown
below. A cardboard shroud was constructed to approximate the size of a typical power
supply, and fitted with a 12 V, 50 mm, 0.27 A fan (Yate Loon D50SH-12C), driven by an
external DC supply. The fan was oriented to exhaust from the box. Fan voltage was set
to 8 VDC for the measurements shown below. The back side of the box was left open to
facilitate measurements with a thermal camera. The main output diodes (D6 and D7) and
the output diode snubber resistor (R37) were not accessible to the thermal camera, so
these were fitted with #30 AWG type T thermocouples soldered to the device mounting
tabs for thermal measurements, or in the case of the resistor, attached to the resistor
body using thermal epoxy. Results are shown in Section 13.2.
Figure 53 – Test Set-up Showing Fan.
第53页（共59页）
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13.1 热图片
Figure 54 – Standby Transformer T2, Visible Light
View.
Figure 55 – Standby Transformer T2 Thermal Image,
Full Load, Room Temperature.
Figure 56 – Standby Output Rectifier D16, Visible
Light View.
Figure 57 – Standby Output Rectifier D16 Thermal
Image, Full Load, Room Temperature.
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Figure 58 – Main Output Choke L1, Visible Light
View.
Figure 59 – Main Output Choke L1 Thermal Image,
Full Load, Room Temperature.
Figure 60 – Main Output Transformer T1, Visible
Light View.
Figure 61 – Main Output Transformer T1 Thermal
Image, Full Load, Room Temperature.
第55页（共59页）
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DER-368：使用TFS7703H设计的190 W一体机PC电源
Figure 62 – HiperTFS-2 IC U6 , Visible Light View.
Figure 63 – HiperTFS-2 IC U6 Thermal Image, Full
Load, Room Temperature.
13.2 主输出整流管的热电耦测量
Position
Temperature
THM1 (D7)
63 °C
THM2 (D6)
64 °C
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THM3 (R37)
62 °C
THM4 (AMB)
25 °C
第56页（共59页）
DER-368：使用TFS7703H设计的190 W一体机PC电源
14
12-Nov-13
增益相位图
Figure 64 – Main Output Control Loop, 380 VDC Input, Full Load. Gain Crossover is at 5.42 kHz, with
54.7º Phase Margin.
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DER-368：使用TFS7703H设计的190 W一体机PC电源
15 版本历史
Date
12-Nov-13
Author
SS
Revision
7.1
Description and Changes
Initial Release
Power Integrations, Inc.
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Reviewed
Apps & Mktg
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有关最新产品信息，请访问：www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability.
Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER
INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING,
WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR
PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits’ external to the products)
may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications
assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power
Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS,
HiperLCS, Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET, PI Expert and PI FACTS are trademarks of Power
Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2012 Power Integrations, Inc.
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