Cost Production Worthy Reference Design Only components! Single sided
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TOPSwitch-II Reference Design Board Input, (30W Peak) Output
Cost Production Worthy Reference Design Only components! Single sided board cost thru-hole components Fully assembled tested Easy evaluate modify Extensive performance data efficiency Light weight heat sink required TOPSwitch-II Fully Protected TOPSwitch-II Primary safety current limit Output short circuit protection Thermal shutdown protects entire power supply Designed World Wide Operation Designed IEC/UL safety requirements Meets Class specifications
Figure Board Overall Physical Dimensions.
1.69
3.57
1.06
PI-2058-041698
PARAMETER Input Voltage Range Input Frequency Range Temperature Range Output Voltage 1.0A) Output Power (continuous) Output Power (peak) Line Regulation (85-265 VAC) Load Regulation (10%-100%) Efficiency Output Ripple Voltage Safety
LIMITS 50°C 25°C 50°C UL1950 (VFG243 CISPR22
Description
reference design board example very cost production worthy power supply design using TOPSwitch family Three-terminal Off-line Switchers from Power Integrations. intended help TOPSwitch users develop their products quickly providing basic design that easily modified particular application. most cases, minor change transformer different output voltage that needed. Multiple output voltages obtained just easily. constant current constant power output implemented with addition cost components. Typical applications include AC-DC adapters laptops, notebooks PDAs, battery chargers cellular telephones, power tools camcorders, VTR/VCR, video game, appliance satellite decoder power supplies.
Figure Table Electrical Parameters.
July 1997
P6KE200
50SQ100
+12V
UF4005
1N4148 PC817A
TOPSwitch-II
CONTROL
3.15
TOP224P
1N5241B
PI-2053-041698
Figure Schematic Diagram Power Supply.
POWER INTEGRATIONS INC. Rev.
COMPONENT SIDE SHOWN
PI-2059-062697
Figure Component Legend RD5.
General Circuit Description
low-cost, flyback switching power supply using TOP224P integrated circuit. circuit shown Figure produces power supply that operates from input voltage. output directly sensed optocoupler Zener diode VR2. output voltage determined Zener diode (VR2) voltage voltage drops across optocoupler (U2) resistor Other output voltages also possible adjusting transformer turns ratios value Zener diode VR2. power rectified filtered create high voltage applied primary winding other side transformer primary driven integrated high-voltage MOSFET within TOP224. clamp leading-edge voltage spike caused transformer leakage inductance safe value reduce ringing.
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Component Listing
Reference Value VAC, VAC, Part Number 2KBPC06M 381LX470M400H012 ECA-1VFQ561 ECE-A1VGE221 RPE131R104M50 ECE-A1AG470 F1772-410-2000 DE1110E102M ACT4K-KD WKP102MCPE.OK PME294RB4100M UF4005 50SQ100 1N4148 622LY-3R3M ELF15N005A 5043CX39R00J 5043CX150R0J 5043CX6R800J TRD5 TOP224P PC817A P6KE200 1N5241B 19372K, 3.15A Manufacturer General Instrument Cornell-Dubilier Panasonic Panasonic Murata Panasonic Roederstein Murata Roederstein) Rifa) General Instrument International Rectifier National Semiconductor Toko Panasonic Philips Philips Philips Custom Power Integrations Sharp General Instrument Motorola Wickman
T1**
Schottky Switching
Zener Zener 3.15
Figure Parts List Series Connected, Y2-Capacitors Such Murata DE7100F222MVA1-KC replace C7). available from Premier Magnetics (714) 362-4211 POL-12017, from Coiltronics (561) 241-7876 CTX00-13742.
power secondary winding rectified filtered create output voltage. provide slight pre-load output improve load regulation light loads. also provides bias current Zener improve regulation. bias winding rectified filtered create bias voltage TOP224P. Y1-capacitor attenuate common-mode emission currents caused high-voltage switching waveforms DRAIN side primary winding primary secondary capacitance. attenuate differential-mode emission currents caused fundamental harmonics primary current waveform. filters internal MOSFET gate drive charge current spikes CONTROL pin, determines auto-restart frequency, together with compensates control loop. circuit performance data shown Figures 6-18 were measured with voltage applied RD5. Load Regulation (Figure amount change output voltage given change output current referred load regulation. output stays within from
100% rated load current. TOPSwitch on-chip overtemperature protection circuit will safely shut down power supply under persisting overload conditions. Below minimum load, output rises slightly TOPSwitch minimum duty cycle. Line Regulation (Figure amount change output voltage given change input voltage called line regulation. maximum change output voltage within Efficiency (Line Dependent) Efficiency ratio output power input power. curves Figures show efficiency changes with input voltage. Efficiency (Load Dependent) curves Figures show efficiency changes with output power inputs. Power Supply Turn Sequence internal switched, highvoltage current source provides initial bias current TOPSwitch when power first applied. waveforms shown
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General Circuit Description (cont.)
Figure illustrate relationship between high-voltage output voltage. Capacitor charges peak input voltage before TOPSwitch turns delay (typical) caused time required charge auto-restart capacitor this point power supply turns shown. Figure shows output voltage turn transient well family curves associated with additional soft-start capacitor. soft-start capacitor placed across range value from shown. Line frequency ripple voltage shown Figure input output. Switching frequency ripple voltage shown Figure same test condition. power supply transient response step load change from 1.25 1.67 (75% 100%) shown Figure Note that response quick well damped. designed meet worldwide safety (VDE specifications. Measured conduction emissions shown Figure Figure VAC. Thermal Considerations utilizes printed circuit copper TOPSwitch heatsinking. output, heatsink area approximately 1.25 cm2). copper area required heatsinking output outlined non-component side board, approximately 0.56 (3.6 cm2). printed circuit board utilizes copper cladding. Printed circuit boards with lighter cladding will require apertures solder mask build-up effective trace thickness.
Transformer Specification
electrical specifications construction details transformer TRD5 shown Figures Transformer TRD5 supplied with reference design board. This design utilizes EI25 core triple insulated wire secondary winding. triple insulated wire allows transformer constructed using smaller core bobbin than conventional magnet wire design elimination margins required safety spacing conventional design. conventional margin wound transformer desired, design Figures 21-22 used. This design (TRD5-1) uses EEL22 core bobbin accommodate margins required meet international safety standards when using magnet wire rather than triple insulated wire, same pinout printed circuit foot print TRD5. transformer approximately taller than triple insulated wire design inclusion creepage margins required meet international safety standards.
PI-2062-070297
Output Voltage Nominal)
Output Voltage Nominal)
1.67
Load Current
Input Voltage (VAC)
0.33
Load Current
Figure Load Regulation
Input Voltage (VAC)
Figure Line Regulation
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PI-2063-070297
PI-2064-070297
Output Efficiency
Output Efficiency
Input Voltage (VAC)
Figure Efficiency Input Voltage, Output
Input Voltage (VAC)
Figure Efficiency Input Voltage, Output
PI-2067-070297
PI-2066-070297
Output Efficiency
Output Efficiency
Output Power
Figure Efficiency Output Power, Input
PI-2068-070297
Output Power
Figure Efficiency Output Power, Input
PI-2069-070297
VOLTAGE
Output Voltage
OUTPUT VOLTAGE
PI-2065-070297
Time (ms)
Time (ms)
Figure Turn Delay
Figure Output Voltage Turn Transient Soft Start Capacitor
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PI-2070-070297 PI-2071-070297
Output Voltage (mV)
Output Voltage (mV)
Time (ms)
Time (µs)
Figure Line Frequency Ripple, Output Output Current Output Voltage (mV)
Figure Switching Frequency Ripple, Output
-100
Time (ms) Figure Transient Load Response (75% 100% load)
PI-2061-040197
PI-2072-070297
Limit (VFG243A)
Limit (VFG243A)
Amplitude (dBmV)
0.01
Amplitude (dBmV)
0.01
Frequency (MHz)
Figure Characteristics Input.
Frequency (MHz)
Figure Characteristics Input.
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PI-2060-040197
Triple-insulated
FUNCTION HIGH-VOLTAGE TOPSwitch DRAIN PRIMARY-SIDE COMMON VBIAS RETURN OUTPUT
CORE# PC40 EI25-Z (TDK) nH/T2 BOBBIN# BE-25-118CP (TDK)
ELECTRICAL SPECIFICATIONS
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance minute, from pins pins Between pins pins Between Pins (All other windings open) Between Pins (All other windings open) Between Pins (Pins shorted) 3000 (min) ±10% (min) (max)
NOTE: inductance measurements should made
PI-2054-050798
Figure Electrical specification transformer TRD5
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TAPE
SECONDARY BIAS PRIMARY
WINDING INSTRUCTIONS
Primary layers) Start Wind turns heavy nyleze magnet wire layers. Finish layer 10.8 wide polyester tape basic insulation. Start Wind turns parallel strands heavy nyleze magnet wire. Space turns evenly across bobbin form single layer. Finish layer 10.8 wide polyester tape basic insulation. Start Pins Wind bifilar turns Triple Insulated Wire. Finish Pins layers 10.8 wide polyester tape insulation. Assemble secure core halves. Impregnate uniformly using varnish.
Basic Insulation Bifilar Bias Winding
Basic Insulation Double Bifilar Secondary Winding Outer Insulation Final Assembly
Triple insulated wire sources. P/N: T28A01TXXX-3 Rubudue Wire Company 5150 Palma Avenue Suite Anaheim Hills, 92807 (714) 693-5512 (714) 693-5515 P/N: order description Furukawa Electric America, Inc. Westpark Drive Suite Peachtree City, 30269 (770) 487-1234 (770) 487-9910 P/N: order description Furukawa Electric Co., 6-1, Marunouchi 2-chome, Chiyoda-ku, Tokyo 100, Japan 81-3-3286-3226 81-3-3286-3747
PI-2055-050798
Figure Construction details transformer TRD5.
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FUNCTION HIGH-VOLTAGE TOPSwitch DRAIN PRIMARY-SIDE COMMON VBIAS RETURN OUTPUT
CORE# PC40 EE22/29/6-Z (TDK) nH/T2 BOBBIN# 2204 (Ying Chin)
ELECTRICAL SPECIFICATIONS
Electrical Strength Creepage Primary Inductance Resonant Frequency Primary Leakage Inductance minute, from pins pins Between pins pins Between Pins (All other windings open) Between Pins (All other windings open) Between Pins (Pins shorted) 3000 (min) ±10% (min) (max)
NOTE: inductance measurements should made
PI-2057-050798
Figure Electrical specification transformer TRD5-1.
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TAPE
SECONDARY BIAS TAPE MARGINS PRIMARY
SLEEVING
WINDING INSTRUCTIONS
Primary Margins Tape margins with wide polyester tape. Match height with primary bias windings. Start Wind layer (approximately turns) heavy nyleze magnet wire from bottom (pin side) top. layer 12.2 wide polyester tape over first primary layer basic insulation. Continue winding remaining primary turns from bottom. Finish Sleeve start finish with Teflon sleeving. layer 12.2 wide tape basic insulation. Start Wind bifilar turns heavy nyleze magnet wire from bottom top. Spread turns evenly across bobbin. Finish Sleeve start finish leads with Teflon sleeving. layers 18.2 wide polyester tape reinforced insulation. Tape margins with wide polyester tape. Match height with secondary winding. Start Pins Wind bifilar turns heavy nyleze magnet wire from bottom top. Spread turns evenly across bobbin. Finish Pins Sleeve start finish leads with Teflon sleeving. Apply layers 18.2 wide polyester tape outer insulation. Assemble secure core halves. Impregnate uniformly with varnish.
PI-2056-050798
Primary Windings
Basic Insulation Bias Winding
Reinforced Insulation Secondary Windings
Secondary Winding
Outer Insulation Final Assembly
Figure Construction details transformer TRD5-1.
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Power Integrations reserves right make changes products time improve reliability manufacturability. Power Integrations does assume liability arising from device circuit described herein, does convey license under patent rights rights others. Logo TOPSwitch registered trademarks Power Integrations, Inc. ©Copyright 1998, Power Integrations, Inc. Mathilda Avenue, Sunnyvale, 94086 http://www.powerint.com
WORLD HEADQUARTERS NORTH AMERICA WEST Power Integrations, Inc. Mathilda Avenue Sunnyvale, 94086 Main: Customer Service: Phone: Fax: NORTH AMERICA EAST SOUTH AMERICA Power Integrations, Inc. Eastern Area Sales Office 1343 Canton Road, Suite Marietta, 30066 Phone: Fax: EUROPE AFRICA Power Integrations (Europe) Ltd. Mountbatten House Fair Acres Windsor Berkshire 4LE, United Kingdom Phone: Fax: TAIWAN Power Integrations International Holdings, Inc. #508, Chung Hsiao Rd., Sec. Taipei 105, Taiwan Phone: Fax:
KOREA Power Integrations International Holdings, Inc. 402, Handuk Building, 649-4 Yeoksam-Dong, Kangnam-Gu, Seoul, Korea Phone: Fax:
JAPAN Power Integrations, K.K. Keihin-Tatemono Bldg. 12-20 Shin-Yokohama 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222, Japan Phone: Fax:
INDIA (Technical Support) Innovatech Main Road Vasanthnagar Bangalore 560052, India Phone: Fax:
APPLICATIONS HOTLINE World Wide APPLICATIONS World Wide
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