RDR-249

Title
Reference Design Report for 14.5 W Standby
and 300 W Main Power Supply Using
HiperTFS™ TFS762HG
Specification
300 VDC – 385 VDC Input; 5 V, 2.9 A (Standby)
and 12 V, 25 A (Main) Outputs
Application
PC Power Supply
Author
Applications Engineering Department
Document
Number
RDR-249
Date
November 16, 2011
Revision
1.1
Summary and Features
 High efficiency Main and Standby converters
 Remote on/off
 Built-in main and standby undervoltage thresholds protection ensures graceful
power supply start-up and shutdown
 Latching output overvoltage protection
 Integrated high-side driver
 Output short-circuit and open loop protection
 Main transformer reset protection
 Flat standby overload versus input voltage
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>.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
Table of Contents
1 2 3 4 Introduction ................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic ................................................................................................................... 6 Circuit Description ...................................................................................................... 7 4.1 Power Input and Filter ......................................................................................... 7 4.2 Primary Side ........................................................................................................ 7 4.3 Output Rectification ............................................................................................. 8 4.4 Output Feedback ................................................................................................. 9 4.5 Output Overvoltage Protection ............................................................................ 9 5 PCB Layout .............................................................................................................. 10 6 Bill of Materials ......................................................................................................... 12 7 Standby Transformer Specification........................................................................... 15 7.1 Electrical Diagram ............................................................................................. 15 7.2 Electrical Specifications ..................................................................................... 15 7.3 Materials ............................................................................................................ 15 7.4 Transformer Build Diagram ............................................................................... 16 7.5 Transformer Construction .................................................................................. 16 8 Main Transformer Specification ................................................................................ 17 8.1 Electrical Diagram ............................................................................................. 17 8.2 Electrical Specifications ..................................................................................... 17 8.3 Materials ............................................................................................................ 17 8.4 Transformer Build Diagram ............................................................................... 18 8.5 Transformer Construction .................................................................................. 19 9 Main Output Inductor Specification ........................................................................... 20 9.1 Electrical Diagram ............................................................................................. 20 9.2 Electrical Specifications ..................................................................................... 20 9.3 Materials ............................................................................................................ 20 9.4 Winding Instructions .......................................................................................... 20 9.5 Inductor Illustrations .......................................................................................... 20 10 Transformer Design Spreadsheet ......................................................................... 21 11 Performance Data ................................................................................................. 27 11.1 Main and Standby Efficiency ............................................................................. 27 11.2 Full Power Standby Efficiency vs. Equivalent AC Input Voltage ........................ 28 11.3 Standby Efficiency vs. Output Power ................................................................ 29 11.4 Standby Only No-Load Input Power .................................................................. 30 11.5 Main and Standby Voltage Regulation .............................................................. 31 11.5.1 Main Load Regulation ................................................................................ 31 11.5.2 Standby Load Regulation at Equivalent AC Input Voltages........................ 32 11.5.3 Standby Line Regulation at Full Power ...................................................... 33 12 Thermal Performance ........................................................................................... 34 13 Waveforms ............................................................................................................ 35 13.1 Main Drain Voltage and Current, Normal Operation, Full Power ....................... 35 13.2 Standby Drain Voltage and Current, Normal Operation, Full Power .................. 36 13.3 Standby Drain Current and Output Voltage Start-Up Profile.............................. 37 Power Integrations, Inc.
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Page 2 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
13.4 Main Drain Current, and Main and Standby Output Voltage Start-Up Profile ....38 13.5 Main Output Voltage Remote-ON Start-Up Profile.............................................38 13.6 Main or Standby OV Shutdown .........................................................................39 13.7 Full Power Hold-Up Time ...................................................................................40 13.8 Standby Auto-Restart ........................................................................................40 13.9 Main and Standby Full Power Output Short-Circuit ...........................................41 13.10 Main Remote-ON/OFF ...................................................................................42 13.11 Output Ripple Measurements ........................................................................43 13.11.1 Ripple Measurement Technique .............................................................43 13.11.2 Measurement Results .............................................................................44 13.12 Main and Standby Load Transient Response ................................................45 14 Design Notes: ........................................................................................................46 15 Revision History ....................................................................................................47 Important Note:
Although this board is designed to satisfy safety isolation requirements, the engineering
prototype has not been agency approved. Therefore, all testing should be performed
using an AC isolation transformer to the DC power supply or power factor stage used to
provide the input voltage.
Page 3 of 48
Power Integrations
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
1 Introduction
This document is an engineering report describing a 5 V, 2.9 A Standby and a 12 V, 25 A
Main power supply utilizing the TFS762HG device from the HiperTFS family. This
example power supply uses a fixed DC input voltage, but in a typical application, it would
be connected to a PFC boost input stage, delivering approximately 385 VDC to
implement a 300 W power supply with various output voltages. A lab bench DC power
supply capable of 400 VDC at 3 A or an AC input rectifier stage is required supply to the
input for evaluation. It is also possible to use the power factor circuit RDK-236 to provide
the regulated 385 VDC needed to power RDK-249.
Typically PC power supplies have a universal AC input power factor corrected (PFC)
input stage but as the bias standby supply must operate before the PFC stage is active,
the Standby output must operate with the DC equivalent of universal AC input voltages
(85 VAC to 265 VAC and 100 VDC to 400 VDC).
The document contains the power supply specification, schematic, bill of materials,
transformer documentation, printed circuit layout, and performance data.
Figure 1 – Populated Circuit Board Photograph.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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Page 4 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
2 Power Supply Specification
The table below represents the minimum acceptable performance of the design. Actual
performance is listed in the results section.
Description
Symbol
Min
Typ
Max
Units
Comment
VIN
VIN
PIN
100
300
420
420
0.3
VDC
VDC
W
Equivalent to 85 VAC - 295 VAC
380
VOUT1
IOUT1
VRIPPLE1
4.75
0.04
5.25
5
50
V
A
mV
5%, 40 mA minimum load
Output Voltage 2 (main 12 V)
VOUT2
Output Current 2 (main 12 V)
IOUT2
Output Ripple Voltage 2 (main 12 V) VRIPPLE2
11.4
0.1
12.00 12.6
25 28.33
120
V
A
mV
5%, 100mA minimum load
14.5
300
314.5
380
W
W
W
W
ms
For Standby only
For both Main and Standby
%
100% Load
%
100% Load
Input
Standby only Voltage
Main and Standby Voltage
No-load Input Power (324 VDC)
Output
Output Voltage 1 (standby)
Output Current 1 (standby)
Output Ripple Voltage 1 (standby)
Total Output Power 1
Total Output Power 2
Total Output Power 3
Total Peak Output Power
Holdup Time
Efficiency
Main and Standby
Standby Only
Ambient Temperature
POUT1
POUT2
POUT3
PPEAK
5.00
2.9
THOLD_UP 20 ms


86.5
76
20
Equivalent to 230 VAC Standby only
10%
20MHz bandwidth
10%
20 MHz bandwidth
For Main12 V only
For both Main and Standby
For POUT3
o
Forced cooling, sea level
0
50
C
TAMB
Table 1 –Power Supply Specifications Using TFS762HG
Note 1: All measurements performed with 380 VDC input unless otherwise specified
Note 2: For output voltage tolerance and ripple see minimum/maximum allowed current
Note 3: Total peak DC output power will not exceed 365 W at 50 oC with forced cooling
Note 4: Peak Main power is 340 W (excluding Standby)
Note 5: Absolute maximum Standby power is less than 25 W (excluding Main)
Note 6: Full load operation at room temperature beyond 10 minutes requires a 30 CFM
fan
Page 5 of 48
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
3 Schematic
Missing from this schematic are any mechanical/assembly part like mounting holes,
screws, heat-sing brackets etc.
Figure 2 – Schematic.
Power Integrations, Inc.
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Page 6 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
4 Circuit Description
The HiperTFS TFS762HG cost effectively incorporates a low-side 725 V Main MOSFET,
a high-side 530 V Main MOSFET and a 725 V Standby MOSFET, main and standby
controllers, a high-side driver along with thermal shutdown and other fault protection and
other control circuitry in a single package. The device is well suited for high power
applications with both main and standby converter (such as PC power supplies). The
standby operates over a wide input voltage range. The main converter is intended to
accept boosted input voltage from a power-factor correction stage and normally operates
over a range from 385 VDC to 300 VDC
4.1 Power Input and Filter
This circuit is designed for PC power supplies with a Main output power up to 300 W.
Diode D13 provides protection against catastrophic failure in case of reverse input
voltage connection which would cause fuse F1 to open. Capacitor C1 is the bulk energy
storage element providing energy for at least 20 ms at full load from 385 VDC initial input
voltage.
4.2 Primary Side
Components C2, R1, R6 and VR3 form a turn-off clamping circuit that limits the drain
voltage of U6 for both the standby drain and the drain of the low-side Main Drain of the
forward converter. Zener VR3 provides a defined clamp voltage and maintains a
maximum voltage (150 V) on clamp capacitor C2. Most of the leakage and magnetizing
energy is returned back to converter due to the slow recovery aspect of the general
recovery diodes D3 and D4. Shared reset/leakage spike clamp between Main and
Standby reduces component count. The Standby is connected via diode D3 and resistor
R5 and the Main section is connected through D8 and D4 together with R7 and R8.
During the reset time, the Main section is connected to a substantially higher reset
voltage than VIN, hence the Main operating duty cycle of the Main converter can operate
above 50% which lowers RMS switch currents without penalizing holdup time.
The BYPASS (BP) pin along with C12 provides a decoupled operating voltage for the
HiperTFS controller. At start-up the bypass capacitor is charged from an internal device
current source. When the BP pin voltage reaches 5.8 V the standby converter will begin
switching and both the +5 V standby output and primary-side bias voltage will begin to
rise. The output of the bias/auxiliary supply winding is rectified by diode D12 and filtered
by capacitor C20. Output of the bias winding is used to supply power via resistor R16 to
the HiperTFS BP pin during standby only operation. Additional current is provided by Q1
and D10 by the primary bias supply when remote-on switch SW1 activates U3A and U3B
and commands Q1 into an ON state. In a complete PC power supply application, this
voltage is used to supply bias to the PFC controller through J4 connector. The value of
R16 is selected to maintain the minimum 700 A required into BP pin to inhibit the
internal HiperTFS high voltage current source and thus reduce no-load consumption.
Capacitor C12 connected to the BP pin of U6 provides decoupling for the internally
Page 7 of 48
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
regulated 5.85 V supply. Zener diode VR4 provides a voltage reference for Q1 to regulate
the emitter voltage to 12.4 V for a stable 6 mA into BP pin.
The ENABLE (EN) pin is the feedback pin for the Standby controller section. Prior to the
start-up a resistor R27 connected from EN to BP can be detected to select on of several
internal current limits for Standby section. FEEDBACK (FB) pin resistor R25 can also be
used to select one of three Main current limits at start-up in the same manner as the EN
pin. Four different resistor values can be used for R27 to select one of the four internal
current limit configurations for the Standby section, and three different values for R25 to
select one of the three current limit configurations for the Main section. The circuit
presented here uses R27 (280 k) for a standby ILIM of 650 mA and R25 for a Main ILIM of
3.5 A.
The FB pin provides feedback for the Main converter. An increase in current sink from FB
pin to ground will lead to a reduction in the operating duty cycle.
Diode D9 is used to provide the initial power for the bootstrap charging C3 and C6 during
start-up. During this time the high-side MOSFET HS pin is briefly pulled to Source for 12
ms. Once the main converter begins switching after the initial 12 ms bootstrap delay,
diode D5 is used to provide the internal nominal power for the high-side section from the
Main transformer support winding, pins 1 and 2. The normal voltage on C6 during normal
operation is shunt regulated to approximately 12 V. It is necessary to insure at all times a
minimum of 13 V on C3.
Resistors R18, R19, and R36 are used to translate the maximum available OFF time
reset voltage into a current for the R pin and compare with the L pin current to compute
the maximum allowable duty cycle to prevent saturation and also determines the
maximum allowable duty factor as a function of peak on-time flux.
The LINE-SENSE (L) pin provides an input bulk voltage line-sense function. This
information is used by the under-voltage and over-voltage detection circuits for both the
Main and standby sections. This pin can also be pulled down to SOURCE to implement a
remote-ON/OFF of both the Standby and Main supplies simultaneously. Resistors R12,
R13, and R35 are used to translate the input voltage into a current for L pin.
4.3 Output Rectification
For the Standby section, output rectification is provided by diode D11. A low ESR
capacitor, C17, provides filtering with low ripple. Inductor L2 and capacitor C15 form a
post-filter to further reduce switching ripple and noise in the output.
For the Main section diode D7 rectifies during Main on-time and diode D6 is the catch
diode to provide a current discharge path for the output inductor, L1, during the Main offtime. Inductor L1 together with capacitors C10 and C11 form an output filter out switching
output ripple and noise.
Power Integrations, Inc.
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Page 8 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
4.4 Output Feedback
For the Standby section, resistor R34 and R31 form a network divider. The output voltage
of the power supply is divided and fed to the input terminal of error amplifier U7. The
cathode terminal voltage of U2A is controlled by the amplifier inside U7 to maintain the
divider voltage to 2.5 V +/-2%. Change in cathode terminal voltage results in a change of
the current through optocoupler diode inside U2A, which in turn changes the current
through the transistor inside U2B. Capacitor C19 provides strong noise rejection for the
EN pin. When the current sinking from the EN pin exceeds the EN pin threshold current,
the next switching cycle is inhibited, and when the output voltage falls below the feedback
threshold, a conduction cycle is allowed to occur. By adjusting the number of enabled
cycles, output regulation is maintained. As the load reduces, the number of enabled
cycles decreases lowering the effective switching frequency and scales the switching
losses with load. This provides almost constant efficiency down to very light loads, ideal
for meeting energy efficiency requirements.
For the Main section, resistors R9 and R24 are employed to provide the DC reference for
the U5 error amplifier. In a similar manner, U5 controls the optocoupler U1 used to adjust
the operating duty cycle trough the current sink from the FB pin with the main difference
being the FB pin current controls the duty cycle of the main converter in a linear manner
versus the whole cycle on/off control of the standby converter.
4.5 Output Overvoltage Protection
The output OV protection for both Main and Standby is provided through optocoupler U4.
If the feedback loop is broken or for any other internal or external reason, the output
voltage increases over the maximum allowed limit, VR1 and/or VR2 are used to activate
the protection circuit built around U4. When the output of U4B turns on, the current flow
into the BP pin exceeds the latching shutdown threshold current of 15 mA. This will
trigger the latching shutdown feature of HiperTFS and the device stops switching,
protecting the output. The latching condition disables switching until the latch is reset with
source current into the L pin below 10 A.
Page 9 of 48
Power Integrations
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
5 PCB Layout
Figure 3 – Printed Circuit Layout, Bottom Side.
Power Integrations, Inc.
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Page 10 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
Figure 4 – Printed Circuit Layout, Top Side.
Page 11 of 48
Power Integrations
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
6 Bill of Materials
Item
Qty
Ref Des
Description
Mfg Part Number
Mfg
1
1
C1
2
1
C2
270 F, 450 V, Electrolytic, (35 x 35)
EET-ED2W271EA
Panasonic
3.3 nF, 1 kV, Disc Ceramic
NCD332M1KVZ5U
NIC
3
4
C3 C4 C6 C8
4
1
C5
100 nF 25 V, Ceramic, X7R, 0603
ECJ-1VB1E104K
Panasonic
47 nF 16 V, Ceramic, X7R, 0603
ECJ-1VB1C473K
Panasonic
470 pF 50 V, Ceramic, X7R, 0603
5
1
C7
ECJ-1VC1H471J
Panasonic
6
3
C9 C18 C19
1000 pF, 100 V, Ceramic, COG, 0603
C1608C0G2A102J
TDK
7
2
C10 C11
3300 F, 16 V, Electrolytic, Very Low
ESR, 15 m, (12.5 x 35)
EKZE160ELL332MK35S
Nippon Chemi-Con
8
1
C12
1 F, 16 V, Ceramic, X5R, 0603
GRM188R61C105KA93D
Murata
9
1
C13
1 nF, 100 V, Ceramic, X7R, 0805
10
1
C14
470 nF, 50 V, Ceramic, Y5G, 0603
11
2
C15 C17
12
1
C16
330 nF, 16 V, Ceramic, Y5G, 0603
2200 F, 10 V, Electrolytic, Low ESR,
(10 x 25)
13
1
C20
330 F, 35 V, Electrolytic, Low ESR, 68
m, (10 x 16)
14
1
C21
2.2 nF, Ceramic, Y1
ECJ-2VB2A102K
Panasonic
C1608Y5V1H474Z
TDK
10MCZ1000M10X25
Rubycon
ECJ-1VF1C334Z
Panasonic
ELXZ350ELL331MJ16S
Nippon Chemi-Con
440LD22-R
Vishay
15
1
D1
LED, Yellow, 5 mm, 585 nm, 30 mcd
SSL-LX5093YD
Lumex Opto
16
1
D2
LED, Green, 5 mm, 565 nm, 30 mcd
SSL-LX5093GD
Lumex Opto
17
2
D3 D4
1N4007-E3/54
Vishay
200 V, 200 mA, Fast Switching, 50 ns,
DO-35
1000 V, 1 A, Rectifier, DO-41
BAV20
Vishay
18
1
D5
19
2
D6 D7
60 V, 60 A, Dual Schottky, TO-220AB
M6060C-E3/45
Vishay
600 V, 1 A, Ultrafast Recovery, 75 ns,
DO-41
UF4005-E3
Vishay
BAS16HT1G
ON Semi
STPS1045B-TR
ST
UF4001-E3
Vishay
1N5404
Vishay
TRK-24
Kang Tang Hardware
64900001039
Wickmann
021706.3HXP
Littlefuse
CT40-5
ITW Chemtronics
20
2
D8 D9
21
1
D10
22
1
D11
23
1
D12
24
1
D13
25
1
ESIP CLIP1
26
1
F1
27
1
F2
28
1
29
2
30
2
31
2
32
1
GREASE1
HEATSINK
BRACKET RIGHT1
HEATSINK
BRACKET RIGHT2
HEATSINK
BRACKET3
HEATSINK
BRACKET4
75 V, 200 mA, Rectifier, SOD323
45 V, 10 A, Schottky Low Drop, SMD,
DPAK
50 V, 1 A, Ultrafast Recovery, 50 ns,
DO-41
OBS non RoHS use 15-00796-00. 400
V, 3 A, Recitifier, DO-201AD
Heatsink Hardware, Edge Clip xxN (xx
lbs) 14.33 mm L x 6.35 mm W
FUSEHOLDER OPEN 5 X 20 MM PC
MNT
6.3 A, 250 V, Fast, 5 mm x 20 mm,
Cartridge
Thermal Grease, Silicone, 5 oz Tube
Bracket, Heatsink, Right
Custom
Bracket, Heatsink, Left
Custom
HS PAD1 HS PAD2
HEATSINK PAD, TO-220, Sil-Pad 1000
1009-58
Bergpuist
HS1
HEATSINK, RDK249-Diode-Hsink, Alum
5052, 3.00" L x 1.650" W x 0.187" Thk
61-00041-00
Custom
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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Page 12 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
33
1
HS2
34
1
J1
35
1
J1_OPTIO
36
1
J2
37
1
J3
38
1
J4
39
1
JP1
40
3
41
HEATSINK, RDK249-eSIP-Hsink, Alum
5052, 3.00" L x 1.650" W x 0.125" Thk
2 Position (1 x 2) header, 10.16 mm
(0.400) pitch, Vertical
2 Position (1 x 2) header, 10.16 mm
(0.400) pitch, Vertical
2 Position (1 x 2) header, 5 mm (0.196)
pitch, Vertical
CONN HEADER 3POS (1x3).156 VERT
TIN
2 Position (1 x 2) header, 0.1 pitch,
Vertical
61-00042-00
Custom
1706785
Phoenix Contact
39910-0102
Molex
1715022
Phoenix Contact
26-64-4030
Molex
22-23-2021
Molex
Wire Jumper, Insulated, 22 AWG, 0.2 in
C2004-12-02
Gen Cable
JP2 JP3 JP4
Wire Jumper, Insulated, 22 AWG, 0.3 in
C2004-12-02
Gen Cable
5
JP5 JP6 JP7 JP8
JP9
Wire Jumper, Insulated, 22 AWG, 0.5 in
C2004-12-02
Gen Cable
42
2
JP10 JP11
Wire Jumper, Insulated, 22 AWG, 0.7 in
C2004-12-02
Gen Cable
43
1
JP12
Wire Jumper, Insulated, 22 AWG, 0.8 in
44
1
JP13
0 R, 5%, 1/10 W, Thick Film, 0603
45
1
L1
32 H,xA, Power Iron Toroid, 8P
46
1
L2
2.2 H, 6.0 A
47
4
POSTCRKT_BRD_632_HEX1-4
48
1
Q1
NPN, Small Signal BJT, GP SS, 40 V,
0.6 A, SOT-23
49
1
R1
2.2 , 5%, 1 W, Metal Film, Fusible
50
1
R2
51
1
R3
52
2
R4 R29
53
3
R5 R7 R8
54
1
R6
55
1
56
1
57
1
R11
43.2 k, 1%, 1/16 W, Thick Film, 0603
58
2
R12 R19
59
4
R13 R18 R35 R36
1.33 M, 1%, 1/4 W, Thick Film, 1206
MCR18EZHF1334
Rohm
60
1
R14
2 k, 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ202V
Panasonic
61
1
R15
750 , 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF7500V
Panasonic
62
1
R16
7.5 k, 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF7501V
Panasonic
63
1
R17
820 , 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ821V
Panasonic
64
2
R20 R22
4.7 k, 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ472V
Panasonic
65
1
R21
2 k, 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF2001V
Panasonic
66
1
R23
1 k, 5%, 1/4 W, Carbon Film
67
1
R24
68
1
R25
69
1
70
1
71
72
C2004-12-02
Gen Cable
ERJ-3GEY0R00V
Panasonic
SNX-R1533
Santronics USA
RFB0807-2R2L
Coilcraft
561-0375A
Eagle Hardware
MMBT4401LT1G
On Semi
NFR0100002208JR500
Vishay
470 , 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ471V
Panasonic
100 , 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ101V
Panasonic
150 , 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ151V
Panasonic
4.7 , 5%, 1/2 W, Carbon Film
CFR-50JB-4R7
Yageo
100 , 5%, 1/2 W, Carbon Film
CFR-50JB-100R
Yageo
R9
15 k, 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ153V
Panasonic
R10
221 , 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF2210V
Panasonic
ERJ-3EKF4322V
Panasonic
271-1.33M/REEL-RC
Xicon
Post, Circuit Board, Female, Hex, 6-32,
snap, 0.375L, Nylon
1.33 M, 1%, 1/4 W, Metal Film
CFR-25JB-1K0
Yageo
3.92 k, 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF3921V
Panasonic
232 k, 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF2323V
Panasonic
R26
200 , 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ201V
Panasonic
R27
280 k, 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF2803V
Panasonic
1
R28
100 , 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ101V
Panasonic
2
R30 R33
1 k, 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ102V
Panasonic
Page 13 of 48
Power Integrations
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RDR-249 5 V Standby and Single 12 V Main
73
2
R31 R34
74
1
R32
4.75 k, 1%, 1/16 W, Thick Film, 0603
ERJ-3EKF4751V
Panasonic
4.7 k, 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ472V
Panasonic
75
4
RIVET1 RIVET2
RIVET3 RIVET4
76
4
RIVET5 RIVET6
RIVET7 RIVET8
77
1
SCREW1
Rivet, Al, .093 Dia x 0.187 (3/16) L, 100
Deg Countersunk, soft, 1100-F
Aluminum
Rivet, Al, .093 Dia x 0.250 (1/4) L, 100
Deg Countersunk, soft, 1100-F
Aluminum
SCREW MACHINE PHIL 4-40 X 1/4 SS
78
2
SCREW2 SCREW3
SCREW MACHINE PHIL 4-40 X 5/16 SS
79
1
SW1
80
1
T1
81
1
T2
82
1
TP1
83
4
U1 U2 U3 U4
U5 U7
16-Nov-11
SLIDE MINI SPDT PC MNT AU
Olander
Olander
PMSSS 440 0025 PH
Building Fasteners
PMSSS 440 0031 PH
Building Fasteners
1101M2S3CBE2
ITT Ind/C&Kdiv
Custom Transformer. Vertical, 14 pins
Bobbin
Custom Transformer, Vertical, 10 Pins
Bobbin
SNX-R1534
YC-3508
SNX-R1535
YW-360-02B
Santronics USA
Ying Chin
Santronics USA
Yih-Hwa
Test Point, WHT,THRU-HOLE MOUNT
5012
Keystone
Optocoupler, TRAN OUT 4-SMD
OBS see 45-00144-00 2.495 V Shunt
Regulator IC, 2%, -40 to 85C, SOT23
PC817XI1J00F
Sharp
LM431AIM
National
Semiconductor
84
2
85
1
U6
TFS762HG
Power Integrations
86
1
VR1
12 V, 5%, 500 mW, DO-213AA (MELF)
ZMM5242B-7
Diodes Inc
87
1
VR2
4.7 V, 5%, 500 mW, DO-213AA (MELF)
ZMM5230B-7
Diodes Inc
P6KE150A
LittleFuse
MMSZ5243BT1G
ON Semi
4NSLWS
Olander
FWSS 004
Building Fasteners
3049
Keystone
TFS762HG, ESIP16/12
88
1
VR3
150 V, 5 W, 5%, TVS, DO204AC (DO15)
89
1
VR4
13 V, 5%, 500 mW, SOD-123
90
3
WASHER 1, 2, 3
Washer, Lk, #4 SS
91
2
WASHER 4, 5
Washer FLAT #4 SS
92
2
WASHER 6, 7
Washer, Shoulder, Nylon, #4
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 14 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
7 Standby Transformer Specification
7.1
Electrical Diagram
Figure 5 – Transformer Electrical Diagram.
7.2
Electrical Specifications
Electrical Strength
Primary Inductance
Resonant
Frequency
Leakage
Inductance
7.3
1 second, 60 Hz, from pins 1-5 to pins 6-10
Pins 1-2, all other windings open, measured at 100 kHz,
0.4 VRMS
Pins 1-2, all other windings open
3000 VAC
850 H, ±10%
2.15 MHz Min
Pins 1-2, with secondary pins shorted, measured at 100 kHz,
0.4 VRMS
Materials
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Description
Core: TDK EE25 part #: PC40EE25.4-Z
Bobbin: EE25, Vertical, 10 pins, (5/5), Yhi Hwa part #: YW-360-02B
Magnet wire: #29 AWG
Magnet wire: #33 AWG
Magnet wire: #20 AWG Triple Insulated Wire
Tape: 3M 1298 Polyester Film, 2 mils thick, 10.8 mm wide
Varnish
Page 15 of 48
Power Integrations
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18 H Max
RDR-249 5 V Standby and Single 12 V Main
7.4
16-Nov-11
Transformer Build Diagram
Figure 6 – Transformer Build Diagram.
7.5
Transformer Construction
Winding
Preparation
WD1: 1st Primary
Insulation
WD2: Auxiliary
Insulation
WD3: Secondary
Insulation
WD4: 2nd Primary
Insulation
Finish
Position the bobbin on the mandrel such that the pin side is on the left side of
bobbin mandrel. Winding direction is clock-wise direction
Start at pin 1, wind 33 turns of wire item [3] from left to right with tight tension in
one layer, at the last turn bring the wire back to the left and terminate at pin 4
2 layers of tape item [6]
Start at pin 3, wind 12 quad-filar turns of wire item [4] from left to right also with
tight tension in one layer, at the last turn bring the wire back to the left and
terminate at pin 5
2 layers of tape item [6]
Start at pin 9, 10 wind 4 bi-filar turns of wire item [5] from left to right also with
tight tension in one layer, at the last turn bring the wire back to the left and
terminate at pin 6, 7
2 layers of tape item [6]
Start at pin 4, wind 32 turns of wire item [3] from right to left with tight tension in
one layer, at the last turn bring the wire back to the right and terminate at pin 2
3 layers of tape item [6]
Assemble, grind the cores to get 2.15 mH and secure with tape. Varnish [7]
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 16 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
8 Main Transformer Specification
8.1
Electrical Diagram
Figure 7 – Transformer Electrical Diagram.
8.2
Electrical Specifications
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage
8.3
1 second, 60 Hz, from pins 1-7 to pins 8-14
Pins 2-6, all other open, measured at 50 kHz,
0.4 VRMS
Pins 2-6, all other open
Pins 2-6, with pins 8-14 shorted, measured at
50 kHz, 0.4 VRMS
3000 VAC
23 mH, ±25%
200 kHz (Min.)
25 H (Max.)
Materials
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
Description
Core: TDK part #:PC40HEER35-Z
Bobbin: EER35, Vertical, 14 pins, (7/7), YingChin part #: YC-3508
Magnet wire: #24 AWG Heavy Nyleze (Solderable Polyurethane-Nylon, Class 130°C Type B)
Magnet wire: #31 AWG Heavy Nyleze (Solderable Polyurethane-Nylon, Class 130°C Type B)
Copper Foil: 8 mils thick (see Fig. 3)
Tape: 3M 1298 Polyester Film, 2 mil thick, 25.5 mm wide
Tape: 3M 1298 Polyester Film, 2 mil thick, 36.0 mm wide
Tape: 3M 44 Margin tape (cream), 3.0 mm wide
Tape: 3M 44 Margin tape (cream), 6.0 mm wide
Varnish
Page 17 of 48
Power Integrations
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RDR-249 5 V Standby and Single 12 V Main
8.4
16-Nov-11
Transformer Build Diagram
Figure 8 – Transformer Build Diagram.
4 x #20AWG
4 x #20AWG
Copper Foil tape item[5]
Outer tape item[7]
24.0mm
36.0mm
9.0mm
425.0mm
9.0mm
Figure 9 – Copper Foil Preparation.
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 18 of 48
16-Nov-11
8.5
RDR-249 5 V Standby and Single 12 V Main
Transformer Construction
Winding Preparation
Margin Tape
WD1: 1st Half Primary
Insulation
Copper Foil
WD2: Secondary
Insulation
Margin Tape
WD3: Support
Insulation
Margin Tape
WD4: 2nd Half
Primary
Insulation
Finish
Page 19 of 48
Position the bobbin on the mandrel such that the pin side is on the left side of
bobbin mandrel. Winding direction is clock-wise direction
Place margin tape 6.0 mm item [9] for the left side and 3.0 mm item [8] for the
right side matching with height of WD1
Start at pin 2, wind 44 turns of wire item [3] from left to right and right to left in 1
½ layers and terminate at pin 4
2 layers of tape item [6]
Prepare the copper foil as in above figure
Use copper foil item [5], start at pins 13, 14, wind 7 turns with tight tension and
end at pins 9, 10
2 layers of tape item [6]
Place margin tape 6.0mm item [9] for the left side and 3.0mm item [8] for the
right side matching with height of WD3
Start at pin 1, wind 5 turns item [4] from left to right, at the last turn bring the
wire back to the left to terminate at pin 2
2 layers of tape item [6]
Place margin tape 6.0 mm item [9] for the left side and 3.0 mm item [8] for the
right side matching with height of WD4
Start at pin 4, wind 44 turns of wire item [3] from left to right and right to left in 1
½ layers and terminate at pin 6
2 layers of tape item [6]
Assemble and secure the cores with tape. Varnish item [7]
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
9 Main Output Inductor Specification
9.1
Electrical Diagram
Figure 10 – Inductor Electrical Diagram.
9.2
Electrical Specifications
Core Effective Inductance
Inductance (LCM)
9.3
9.5
AL = 95 nH/N²
35.8 H ±10%
Materials
Item
[1]
[2]
9.4
Pins 1-2 measured at 100 kHz
Description
Toroid: Micrometals, part#: T132-52
Magnet Wire: #17 AWG, solderable double coated
Winding Instructions
 Use 4 wires of item [2] about 100 cm long, wind 19 turns in ~2 layers firmly and in
one direction. Start with FL1, FL2, FL3, FL4, end with FL5, FL6, FL7, FL8, and
leave ~ ½” long.
 Tin all leads ~½”
Inductor Illustrations
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Page 20 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
10 Transformer Design Spreadsheet
(Note – Output current is made 4.20 A in the spreadsheet to account for load on the auxiliary output)
HiperTFS_Twoswitch_Forward_092110
; Rev.1.04; Copyright
HiperTFS_092110 Two-switch Forward
Power Integrations 2010
INPUT
INFO
OUTPUT
UNIT
Transformer Design Spreadsheet
HiperTFS MAIN OUTPUT (TWO-SWITCH FORWARD STAGE)
OUTPUT VOLTAGE AND CURRENT
VMAIN
12.00
V
Main output voltage
IMAIN
25.00
A
Main output current
VOUT2
V
Output2 voltage
IOUT2
A
Output2 current
POST REGULATED OUTPUT
!!!! Info. No Selection for post-regulator Post Regulator
NONE
Info
select 'NONE' if not using post-regulator
Select source of input voltage for post
V_SOURCE
V
regulator
VOUT3
0.0
V
Enter postregulator output voltage
IOUT3
0.0
A
Enter post rehulator output current
n_PR
1
Enter postregulator efficiency (Buck only)
COUPLED-INDUCTOR (LOW POWER) DERIVED OUTPUT
Coupled-Inductor derived (low power) output
VOUT4
12.00
V
voltage (typically -12 V)
Coupled-Inductor derived (low power) output
IOUT4
0.10
A
current
POUT(Main)
301.2
W
Total output power (Main converter)
Peak Output power(Main converter). If there
POUT_PEAK(Main)
340.00
340.0
W
is no peak power requirement enter value
equal to continuous power
Continuous output power from Standby
POUT(Standby)
10.3
W
power supply
POUT_PEAK(Standby)
14.5
W
Peak output power from Standby section
POUT(System Total)
311.5
W
Total system continuous output power
POUT_PEAK(System Total)
W
Total system peak output power
DC bias voltage from main transformer aux
VBIAS
17.00
V
winding
INPUT VOLTAGE AND UV/OV
Input Capacitance. To increase CMIN,
CIN
269.92
uF
increase T_HOLDUP
T_HOLDUP
20.00
ms
Holdup time
Minimum input voltage to guarantee output
VMIN
300
V
regulation
VNOM
380
V
Nominal input voltage
VMAX
420
V
Maximum DC input voltage
UV / OV / UVOV
min
max
VUV OFF
236.0
287.9
V
Minimum undervoltage On-Off threshold
Maximum undervoltage Off-On threshold
VUV ON
300.0
344.7
V
(turn-on)
VOV ON
480.4
V
Minimum overvoltage Off-On threshold
Minimum overvoltage On-Off threshold (turnVOV OFF
664.5
V
off)
RR
4.00
M-ohm
R pin resistor
Line Sense resistor value (L-pin) - goal seek
RL
4
4.00
M-ohm
(VUV OFF) for std 1% resistor series
ENTER DEVICE VARIABLES
Device
TFS762
Selected HiperTFS device
Chosen Device
TFS762
ILIMIT_MIN
3.25
A
Device current limit (Minimum)
ILIMIT_TYP
3.50
A
Device current limit (Typical)
ILIMIT_MAX
3.75
A
Device current limit (Maximum)
fSMIN
61500
Hz
Device switching frequency (Minimum)
fS
66000
Hz
Device switching frequency (Typical)
Page 21 of 48
Power Integrations
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RDR-249 5 V Standby and Single 12 V Main
fSMAX
70500
KI
1.0
232.0
3.25
3.05
0.448
5.28
VCLAMP
k-ohms
A
ohms
0.45
VDS
Clamp Selection
Hz
1.0
R(FB)
ILIMIT SELECT
RDS(ON)
DVNOM_GOAL
16-Nov-11
V
CLAMP TO RAIL
150.00
150.00
V
570.00
V
DIODE Vf SELECTION
VDMAIN
0.5
V
VDOUT2
0.5
V
VDOUT3
VDB
TRANSFORMER CORE SELECTION
Core Type
EER35
0.5
0.7
V
V
VDSOP
Bobbin
AE
LE
AL
BW
M
P/N:
P/N:
cm^2
cm
nH/T^2
mm
4.5
mm
LG MAX
0.002
mm
L
3.00
NMAIN
7.0
NS2
0.0
NBIAS
5
VOUT2 ACTUAL
0.0
V
VBIAS_ACTUAL
16.3
V
TRANSFORMER DESIGN PARAMETERS
NP
88
BM_MAX
1791
Gauss
BM PK-PK
2714
Gauss
BP_MAX
2321
Gauss
BP PK-PK
3516
Gauss
LP MIN
20.60
mHenries
IMAG
0.123
A
OD_P
0.58
mm
23
AWG
AWG_P
DUTY CYCLE VALUES (REGULATION)
DVMIN
DVNOM
DVMAX
Main output diodes forward voltage drop
Secondary output diodes forward voltage
drop
3rd output diodes forward voltage drop
Bias diode forward voltage drop
Selected core type
EER3
5
EER35_BOBBIN
1.07
9.08
2770
26.1
Core
Device switching frequency (Maximum)
Select Current limit factor (KI=1.0 for default
ILIMIT, or select KI=0.8 or KI=0.6)
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
Select either "CLAMP TO RAIL" (default) or
"CLAMP TO GND"
Asymmetric Clamp Voltage
Maximum HiperTFS Drain voltage (at
VOVOFF_MAX)
0.57
0.45
0.40
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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PC40EER35-Z
BEER-35-1116CPH
Core Effective Cross Sectional Area
Core Effective Path Length
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
Bobbin safety margin tape width (2 * M =
Total Margin)
Maximum zero gap tolerance, default 2um
Transformer primary layers (split primary
recommended)
Main rounded turns
Vout2 rounded secondary turns
(Independent windings)
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 = 5 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)
Minimum primary magnetizing inductance
(assumes LG MAX=2um)
Peak magnetizing current at minimum input
voltage
Primary wire outer diameter
Primary Wire Gauge (rounded to maximum
AWG value)
Duty cycle at minimum DC input voltage
Duty cycle at nominal DC input voltage
Duty cycle at maximum DC input voltage
Page 22 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
DOVOFF MIN
0.25
Duty cycle at over-voltage DC input
voltage(DOVOFF_MIN)
MAXIMUM DUTY CYLE VALUES
DMAX_UVOFF_MIN
DMAX_VMIN
DMAX_VNOM
DMAX_VMAX
DMAX_OVOFFMIN
CURRENT WAVESHAPE PARAMETERS
0.62
0.60
0.58
0.52
0.33
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
Max duty clamp cycle at VOVOFF_MAX
IP
2.39
A
IP_PEAK
2.69
A
IPRMS(NOM)
1.38
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
0.27
Pow Iron
T132-52(O.D)=33)
Pow Iron
T132-52(O.D)=33)
80.5
mm^2
LE
79.6
AL
95.0
BW
55.9
VE
6410.0
Powder cores (Sendust and Powdered Iron) Cores
MUR
75.0
H
64.9
mm
nH/T^2
mm
mm^3
AT/cm
MUR_RATIO
0.48
LMAIN_ACTUAL
16.4
uH
LMAIN_0bias
34.3
uH
LOUT2
0.0
uH
2919.0
402.8
Gauss
Gauss
BM_IND
BAC_IND
Turns
INDUCTOR TURNS
MULTIPLIER
2.7
19.0
0.0
NOUT4_INDUCTOR
12.0
Ferrite Cores
LMAIN_ACTUAL
LOUT2
LG
Target BM
BM_IND
BAC_IND
Turns
NMAIN_INDUCUTOR
NAUX_INDUCTOR
N_BIAS
Wire Parameters
Total number of layers
IRMS_MAIN
IRMS_AUX
AWG_MAIN
OD_MAIN
Page 23 of 48
N/A
N/A
N/A
N/A
N/A
N/A
uH
uH
mm
Gauss
Gauss
Gauss
N/A
N/A
N/A
1.06
25.0
0.0
15.0
1.5
Core Effective Path Length
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
Relative permiability of material
Magnetic field strength
Percent of permiability 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 auxilliary 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)
2.7
NMAIN_INDUCTOR
NOUT2_INDUCTOR
Current ripple factor of combined Main and
Output2 outputs
Select core type
Coupled Inductor - Core size
Core Effective Cross Sectional Area
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
A
A
AWG
mm
Total number of layers for chosen toroid
RMS current through main inductor windings
RMS current through aux winding
Main inductor winidng wire gauge
Main winding wire gauge outer diameter
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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RDR-249 5 V Standby and Single 12 V Main
FILAR_MAIN
RDC_MAIN
2.0
4.3
AC Resistance Ratio (Main)
16-Nov-11
mohm
4.0
CMA_MAIN
J_MAIN
AWG_AUX
OD_MAIN
FILAR_AUX
RDC_AUX
260.5
13.6
0.0
N/A
2.0
0.0
AC Resistance Ratio (Aux)
0.00
CMA_AUX
Info
CMA
A/mm^2
AWG
mm
mohm
0.0
CMA
0.0
A/mm^2
Number of parallel strands for main output
Reisstance 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
Auxilliary winding wire gauge outer diameter
Number of parallel strands for aux output
Reisstance 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 auxilliary winding
J_AUX
Estimated Power Loss
PCOPPER_MAIN
PCOPPER_AUX
PCORE
PTOTAL
SECONDARY OUTPUT PARAMETERS
ISFWDRMS
ISFWD2RMS
2.7
0.0
2.2
4.9
W
W
W
W
Copper loss in main inductor windinig
Copper loss in aux inductor winidgs
Total core loss
Total losses in output choke
18.99
0.00
A
A
Max. fwd sec. RMS current (at DVNOM)
Max. fwd sec. RMS current (at DVNOM)
ISCATCHRMS
ISCATCH2RMS
21.16
0.00
A
A
Max. catch sec. RMS current (at DVNOM)
Max. catch sec. RMS current (at DVNOM)
IDAVMAINF
14.18
A
IDAVMAINC
14.92
A
IDAVOUT2F
0.00
A
IDAVOUT2C
0.00
A
IRMSMAIN
1.98
A
IRMSOUT2
0.00
A
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
% Derating
VPIVMAINF
100%
45.3
V
VPIVMAINC
100%
33.4
V
VPIVOUT2F
100%
0.0
V
VPIVOUT2C
100%
0.0
V
VPIVB
100%
32.4
V
HiperTFS STANDBY SECTION (FLYBACK STAGE)
ENTER APPLICATION VARIABLES
VACMIN
85
VACMAX
265
fL
50
VO_SB
5.00
V
V
Hz
V
IO_SB
2.00
A
IO_SB_PK
POUT_SB
2.90
10
W
POUT_SB_TOTAL
10.32
W
POUT_SB_PK
14.7
W
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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Main Forward Diode peak-inverse voltage (at
VDSOP)
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)
Continuous Output Power
Total Standby power (Includes Bias winding
power)
Peak Standby Output Power
Page 24 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
n
0.70
Z
0.50
tC
3.00
ENTER HiperTFS STANDBY VARIABLES
Select Current Limit
STD
ILIM_MIN
ILIM_TYP
ILIM_MAX
R(EN)
fSmin
ms
Standard Current Limit
0.605
0.650
0.696
280.0
124000
A
A
A
k-ohms
Hz
50.19
A^2kHz
90
V
10
V
VD_SB
KP
0.5
0.71
V
KP_TRANSIENT
0.36
ENTER BIAS WINDING VARIABLES
VB
IB
PB
VDB
NB
VZOV
UVLO VARIABLES
16.00
20.00
0.32
0.70
9.11
22.00
V
mA
W
V
RLS
4.00
M-Ohms
I^2fmin
VOR
90.00
VDS
V_UV_ACTUAL
102
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type
EE25
EE25
EE25
Core
EE25_BOBBIN
Bobbin
AE
0.404
LE
7.34
AL
1420
BW
10.2
M
0
L
NS_SB
DC INPUT VOLTAGE PARAMETERS
VMIN_SB
VMAX_SB
CURRENT WAVEFORM SHAPE PARAMETERS
2
3
115.65
374.77
V
V
P/N:
P/N:
cm^2
cm
nH/T^2
mm
mm
Bias Winding Voltage
Bias winding Load current
Bias winidng power
Bias Winding Diode Forward Voltage Drop
Bias Winding Number of Turns
Over Voltage Protection zener diode voltage.
Line sense resistor (from Main converter
section)
Typical DC start-up voltage
Enter Transformer Core
PC40EE25-Z
EE25_BOBBIN
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
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
0.46
IAVG
IP_SB
IR_SB
IRMS_SB
TRANSFORMER PRIMARY DESIGN PARAMETERS
0.20
0.60
0.43
0.32
A
A
A
A
841.65
uH
Page 25 of 48
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)
HiperTFS 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
V
V
DMAX_SB
LP_SB
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
Typical Primary Inductance. +/- 10% to
ensure a minimum primary inductance of 765
uH
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
LP_TOLERANCE
NP_SB
ALG
10
49
349
%
nH/T^2
BM
2952
Gauss
BAC
1050
Gauss
ur
LG
BWE
2053
0.11
20.4
mm
mm
OD
0.42
mm
INS
0.06
mm
DIA
0.35
mm
AWG
28
AWG
CM
161
Cmils
506
Cmils/Amp
CMA
Info
TRANSFORMER SECONDARY DESIGN PARAMETERS
Lumped parameters
ISP
9.89
ISRMS
5.65
IRIPPLE
5.29
CMS
A
A
A
1131
Cmils
19
AWG
VDRAIN
584
V
PIVS
28
V
AWGS
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
CAN DECREASE CMA < 500 (decrease
L(primary layers),increase NS,use smaller
Core)
Peak Secondary Current
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)
VOLTAGE STRESS PARAMETERS
Power Integrations, Inc.
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Maximum Drain Voltage Estimate (Assumes
20% zener clamp tolerance and an additional
10% temperature tolerance)
Output Rectifier Maximum Peak Inverse
Voltage
Page 26 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
11 Performance Data
All measurements are performed at the PCB connector at room temperature and 380
VDC input. For standby measurements, DC input voltage vas adjusted to match the
equivalent AC voltage.
11.1 Main and Standby Efficiency
92
91
Efficiency (%)
90
89
88
87
86
85
84
0
10
20
30
40
50
60
70
80
90
Output Power Level (%)
Figure 11 – Main and Standby Efficiency [%], Room Temperature, Forced Cooling.
Page 27 of 48
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100
RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
11.2 Full Power Standby Efficiency vs. Equivalent AC Input Voltage
82.6
82.4
82.2
Efficiency (%)
82.0
81.8
81.6
81.4
81.2
81.0
80.8
85
100
115
130
145
160
175
190
205
220
235
250
265
280
Equivalent AC Input Voltage (V)
Figure 12 – Full Power Standby Efficiency [%] vs. AC Input Voltage [V] at Room Temperature
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Page 28 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
11.3 Standby Efficiency vs. Output Power
82
Standby Efficiency (%)
80
78
76
Efficiency for 90 VAC
Efficiency for 115 VAC
74
Efficiency for 230 VAC
Efficiency for 265 VAC
72
0
10
20
30
40
50
60
70
80
90
Standby Output Power (%)
Figure 13 – Standby Efficiency [%], at Room Temperature and Equivalent AC Input Voltage.
Page 29 of 48
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100
RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
11.4 Standby Only No-Load Input Power
180
160
Input Power (mW)
140
120
100
80
60
85
100
115
130
145
160
175
190
205
220
235
250
265
280
Equivalent AC Input Voltage (V)
Figure 14 – Input Power [mW] vs. Input Line Voltage [V], for Zero Standby Load at Room Temperature.
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Page 30 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
11.5 Main and Standby Voltage Regulation
11.5.1 Main Load Regulation
12.073
Main Regulation
12.072
Main Output Voltage (V)
12.071
12.070
12.069
12.068
12.067
12.066
12.065
12.064
0.0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0
22.5
25.0
Main Output Current (A)
Figure 15 – Main Load Regulation, at Room Temperature and 380 VDC Input Voltage.
Page 31 of 48
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27.5
RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
11.5.2 Standby Load Regulation at Equivalent AC Input Voltages
4.98
Regulation at 90 VAC
Regulation at 115 VAC
Standby Output Voltage (V)
4.97
Regulation at 230 VAC
Regulation at 265 VAC
4.96
4.95
4.94
4.93
4.92
0.0
0.3
0.5
0.8
1.0
1.3
1.5
1.8
2.0
2.3
2.5
2.8
3.0
Standby Output Current (A)
Figure 16 – Standby Load Regulation, at Room Temperature and Equivalent AC Input Voltage.
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Page 32 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
11.5.3 Standby Line Regulation at Full Power
4.938
Standby Output Voltage (V)
4.936
4.933
4.931
4.928
4.926
4.923
85
100
115
130
145
160
175
190
205
220
235
250
Equivalent AC Input Voltage (V)
Figure 17 – Line Regulation, at Room Temperature, Full Load.
Page 33 of 48
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265
280
RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
12 Thermal Performance
Full output power operation at room temperature is allowed only for operation time under
10 minutes. It is required to provide forced air cooling for operation at full power for more
than 10 minutes or for over-power tests.
Figure 18 – HiperTFS Device Temperature.
Figure 19 – Board Thermal Image.
.
In case of power components replacement it is important to insure a clean and smooth
surfaces for heat-sink mechanical assembly with thermal conductive grease between any
surface in contact, even for the isolation pad.
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Page 34 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
13 Waveforms
13.1 Main Drain Voltage and Current, Normal Operation, Full Power
Figure 20 – Input Voltage: 380 VDC
Upper: Main Upper MOSFET (Red) VSOURCE,
100 V / div.
Upper: Main Lower MOSFET (Gold) VDRAIN,
100 V / div.
Lower: Main IDRAIN, 500 mA, 10 s / div.
Page 35 of 48
Figure 21 – Input Voltage: 380 VDC
Upper: Main Upper MOSFET (Red) VSOURCE,
100 V / div.
Upper: Main Lower MOSFET (Gold) VDRAIN,
100 V / div.
Lower: Main IDRAIN, 500 mA, 2 s / div.
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
13.2 Standby Drain Voltage and Current, Normal Operation, Full Power
Figure 22 – Input Voltage: 127 VDC
Upper: Standby VDRAIN, 50 V / div.
Lower: Standby IDRAIN, 120 mA, 1 s / div.
Figure 24 – Input Voltage: 127 VDC
Standby VDRAIN, 50 V / div., 10 s / div.
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Figure 23 – Input Voltage: 380 VDC
Upper: Standby VDRAIN, 100 V / div.
Lower: Standby IDRAIN, 100 mA, 1 s / div.
Figure 25 – 380 VDC
Standby VDRAIN, 100 V / div., 10 s / div.
Page 36 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
13.3 Standby Drain Current and Output Voltage Start-Up Profile
Figure 26 – Full Load: 127 VDC Input Voltage.
Upper: VSTBY, 1 V / div.
Lower: Standby IDRAIN, 200 mA, 2 ms / div.
Figure 27 – Full Load: 380 VDC Input Voltage.
Upper: VSTBY, 1V / div.
Lower: Standby IDRAIN, 200 mA, 2 ms / div.
Figure 28 – No-load at 127 VDC Input Voltage
Upper: VSTBY, 1 V / div.
Lower: Standby IDRAIN, 200 mA, 5 ms / div.
Figure 29 – No-load at 380 VDC Input Voltage
Upper: VSTBY, 1 V / div.
Lower: Standby IDRAIN, 200 mA, 5 ms / div.
Page 37 of 48
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
13.4 Main Drain Current, and Main and Standby Output Voltage Start-Up Profile
Figure 30 – No-load: 380 VDC Input Voltage.
Upper (Red): VSTBY, 1 V / div.
Upper (Yellow): VMAIN, 2 V / div.
Lower: Main IDRAIN, 750 mA, 5 ms / div.
For this test the DC input voltage was applied with remote-ON/OFF switch in ON position.
13.5 Main Output Voltage Remote-ON Start-Up Profile
Figure 31 – No-load: 380 VDC Input Voltage.
Upper (Red): VSTBY, 1 V / div.
Upper (Yellow): VMAIN, 2 V / div.
Lower: Main IDRAIN, 750 mA, 5 ms / div.
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Page 38 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
13.6 Main or Standby OV Shutdown
In order to activate the Standby or Main Overvoltage Protection Circuit for testing
purpose, the recommended procedure is to temporarily short-circuit the input side of the
respective optocouplers: U1A for the Main section or U2A for the Standby section.
Without proper signal, the feedback loop will be forced to maximize the control signal and
the Main or the Standby output voltage will increase all the way up to the shut-down limit.
This overvoltage trigger condition will force the current into the BP pin to exceed the
threshold limit and the internal HiperTFS controller to lock-out in a disabled state. For
resetting the lock-out condition, the input voltage must be removed to allow the voltage
on the BP pin to be discharged.
Figure 32 – Standby OV Protection.
Upper (Red): VSTBY, 1 V / div.
Upper (Yellow): VMAIN, 2 V / div.
Lower: Standby IDRAIN, 200 mA, 2 ms / div.
Page 39 of 48
Figure 33 – Main OV Protection.
Upper (Red): VSTBY, 1 V / div.
Upper (Yellow): VMAIN, 2 V / div.
Lower: Main IDRAIN, 750 mA, 2 ms / div.
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
13.7 Full Power Hold-Up Time
Figure 34 – Maximum Hold-Up Time = 22.3 ms
Upper (Yellow): VMAIN, 2 V / div.
Upper (Red): VSTBY, 1 V / div.
Lower: Input VDC, 60 V, 5 ms / div.
After turning OFF the input voltage, the full output power Hold-Up Time from 385 VDC
down to 300 VDC is 20.8 ms. Maximum Hold-Up time (before 12 V Main output losing
regulation, starting from 385 VDC input) is 22.3 ms.
13.8 Standby Auto-Restart
Figure 35 – Maximum Hold-Up Time = 22.3 ms
Upper: Standby VDRAIN, 100 V / div.
Lower: Standby IDRAIN, 100 mA, 1 s / div.
Overloading the standby output with 6 A for 380 VDC input shows repeated restart
attempts every 2.3 s followed by a quick shutdown.
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Page 40 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
13.9 Main and Standby Full Power Output Short-Circuit
For short-circuit testing the recommended procedure is to use MOSFETs like IXYS
IXFN180N25T or equivalent devices with high current capability connected to both Main
and Standby outputs. In Short-Circuit mode only the output connectors and cable wires
will have any significant resistivity. The unit will withstand short-circuit conditions without
any permanent damage, and the outputs will go back to normal after the fault condition is
removed. The Standby controller will try a restart cycle any time when the restart
conditions are satisfied.
Figure 36 – Standby Output Short-Circuit.
Upper: VSTBY, 1 V / div.
Lower: Standby IDRAIN, 200 mA, 50 s / div.
Figure 38 – Main Output Short-Circuit.
Upper: VMAIN, 2 V / div.
Lower: Main IDRAIN, 750 mA, 50
Page 41 of 48
s / div.
Figure 37 – Standby Output Short-Circuit.
Upper: VSTBY, 1 V / div.
Lower: Standby IDRAIN, 200 mA, 100 ms / div.
Figure 39 – Main Output Short-Circuit.
Upper: VMAIN, 2 V / div.
Lower: Main IDRAIN, 750 mA, 100 ms / div.
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
13.10 Main Remote-ON/OFF
Figure 40 – Main Remote-ON: 385 VDC = 28.5 ms.
Upper: VMAIN, 2 V / div.
Lower: Remote-ON, 1 V, 5 ms / div.
Figure 41 – Main Remote-OFF: 385 VDC = 265 s.
Upper: VMAIN, 2 V / div.
Lower: Remote-OFF, 1 V, 5 ms / div.
Main Remote-ON start-up time is measured between Remote-ON/OFF signal going in
ON state and Main 12 V output reaching 11.5 V, and it is 28.5 ms. Main Remote-OFF
shut-down time is measured from Remote-ON/OFF signal going in OFF state and Main
12 V output going down to 11.5 V, and it is 265 s.
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Page 42 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
13.11 Output Ripple Measurements
13.11.1
Ripple Measurement Technique
For DC output ripple measurements, a modified oscilloscope test probe must be utilized
in order to reduce spurious signals due to pickup. Details of the probe modification are
provided in the figures below.
The 5125BA probe adapter is affixed with two capacitors tied in parallel across the probe
tip. The capacitors include one (1) 0.1 F / 50 V ceramic type and one (1) 1.0F/50V
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 5125BA BNC Adapter.
(Modified for ripple measurement, and two parallel decoupling capacitors added)
Page 43 of 48
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RDR-249 5 V Standby and Single 12 V Main
13.11.2
16-Nov-11
Measurement Results
Figure 44 – Standby Output Ripple: 380 VDC
VSTBY, 20 mV / div., 5 s / div. (Full
Load)
Figure 45 – Standby Output Ripple: 380 VDC.
VSTBY, 20 mV / div., 2 ms / div. (Full
Load)
Figure 46 – Main Output Ripple: 380 VDC
VMAIN, 20 mV / div., 5 s / div. (Full
Load)
Figure 47 – Main Output Ripple: 380 VDC
VMAIN, 20 mV / div., 2 ms / div. (Full
Load)
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Page 44 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
13.12 Main and Standby Load Transient Response
The waveform shows the instantaneous output voltage for 33% to 66% step load change.
The voltage step change is under 50 mV for Standby output and under 150 mV for Main
output. For the Standby test the Main output was off, for the Main test the Standby output
was loaded at 50%.
Figure 48 – Standby Step Load: 380 VDC
Upper: VSTBY, 20 mV / div.
Lower: Standby IOUT, 300 mA, 2ms / div.
Page 45 of 48
Figure 49 – Main Step Load: 380 VDC
Upper: VMAIN, 50 mV / div.
Lower: Main IOUT, 2.5 A, 2 ms / div.
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
14 Design Notes:
1. Pay extra attention when mounting the TFS762HG and the eSIP clip. TFS762HG
must be placed flush with the PCB, as close as possible There must be at least 2
mm clearance between clip and TFS762HG edge to avoid short-circuit from
exposed metallic ends to mounting clip.
2. For convenience, two LED footprints are provided for optional visual control. All
no-load tests must be completed without LEDs.
3. J1_OPTIO it is provided at schematic and BOM level as an alternative option only.
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Page 46 of 48
16-Nov-11
RDR-249 5 V Standby and Single 12 V Main
15 Revision History
Date
09-Nov-10
16-Nov-11
Page 47 of 48
Author
AN
KM
Revision
1.0
1.1
Description and changes
Initial Release
Updated BOM and Schematic
Reviewed
Apps & Mktg
Power Integrations
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RDR-249 5 V Standby and Single 12 V Main
16-Nov-11
For the latest updates, visit our website: 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, 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 2010 Power Integrations, Inc.
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Phone: +39-028-928-6000
Fax: +39-028-928-6009
e-mail:
[email protected]
SINGAPORE
51 Newton Road,
#15-08/10 Goldhill Plaza
Singapore, 308900
Phone: +65-6358-2160
Fax: +65-6358-2015
e-mail:
[email protected]
APPLICATIONS HOTLINE
World Wide +1-408-414-9660
Power Integrations, Inc.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
APPLICATIONS FAX
World Wide +1-408-414-9760
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