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| power integrations, inc. 5245 hellyer avenue, san jose, ca 95138 usa. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com title engineering prototype report (ep13) 43 w / 57 w pk, 5 output topswitch ? ? ? ? -gx (top246y) power supply specification 185 - 265 v ac input, 3.3 v / 3 a, 5 v / 3.2 a, 12 v / 0.6 a (1.8 a pk), 18 v / 0.5 a, 30 v / 0.03 a output. (details for 115 v ac conversion included) target applications set top box with internal hard drive, or other multiple output applications author power integrations applications department document number EPR-000013 date 08-may-2001 revision 1.0 features ? compact design (6.875? l x 2.56? w x 1.56? h) ? 43 w steady state output power at 50 c ambient, free convection ? high efficiency (75% minimum at 180 v ac input, maximum continuous load) ? low no-load power consumption (< 0.7 w @ 180 v ac , < 0.8 w @ 265 v ac ) ? multiple section transformer for low cost automated production ? excellent output voltage tracking and cross regulation ? primary soft-start minimizes component stress during start-up ? low conducted emi due to frequency jittering: meets cispr22b/en55022b ? line overvoltage shutdown provides extended line surge protection ? hysteretic thermal shutdown allows automatic supply recovery after fault removal ? low component count with single sided printed circuit board ? surge immunity up to 4 kv (surge or 100 khz ring wave)
EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 2 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com table of contents 1 introduction .................................................................................................................4 2 power supply specification ........................................................................................5 3 schematic ...................................................................................................................6 4 circuit description.......................................................................................................7 5 pcb layout...............................................................................................................10 6 bill of materials.........................................................................................................11 7 transformer specification .........................................................................................13 7.1 electrical specifications.........................................................................................13 7.2 materials................................................................................................................13 7.3 winding instructions ..............................................................................................14 7.4 transformer sources.............................................................................................14 8 transformer spreadsheets .......................................................................................15 8.1 230 v ac , 60 w peak load .....................................................................................15 8.2 230 v ac , 45 w steady state load.........................................................................18 9 performance data.....................................................................................................21 9.1 efficiency...............................................................................................................21 9.2 no-load input power..............................................................................................21 9.3 regulation .............................................................................................................22 9.3.1 maximum load all outputs ..............................................................................22 9.3.2 peak load all outputs......................................................................................22 9.3.3 3.3 v min. load, 12 v peak, other outputs fully loaded ...................................23 9.3.4 12 v min. load, other outputs at maximum load condition..............................23 9.3.5 12 v peak load, 30 v min. load, other outputs at max. load...........................24 9.3.6 5 v and 3.3 v min load, all other outputs maximum .......................................24 10 thermal performance ...............................................................................................25 11 waveforms................................................................................................................26 11.1 drain voltage and current, normal operation...................................................26 11.2 output voltage start-up profile..........................................................................26 11.3 drain voltage and current start-up profile ........................................................27 11.4 load transient response (75% to 100% load step)........................................28 11.5 output ripple measurements ............................................................................29 11.5.1 ripple measurement technique ....................................................................29 11.5.2 measurement results at 180 v ac ...................................................................30 11.5.3 measurement results at 230 v ac ...................................................................31 12 control loop measurements.....................................................................................32 12.1 180 v ac maximum load ....................................................................................32 12.2 230 v ac maximum load ....................................................................................33 12.3 265 v ac maximum load ....................................................................................34 13 conducted emi .........................................................................................................35 14 ac surge and 100 khz ring wave immunity ...........................................................35 14.1 common mode surge, 1.2/50 sec ...................................................................36 14.2 differential mode surge, 1.2/50 sec ................................................................36 14.3 common mode, 100 khz ring wave.................................................................37 14.4 differential mode, 100 khz ring wave ..............................................................37 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 3 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15 appendix a ? ep13, 115 v ac version ...................................................................... 38 15.1 115 vac option power supply specification.................................................... 38 15.2 schematic for ep13 115 v ac -only version........................................................ 39 15.3 ep13 115 v ac version circuit description ........................................................ 40 15.4 ep13 115 v ac transformer drawing ................................................................. 41 15.5 electrical specifications .................................................................................... 41 15.6 materials ........................................................................................................... 42 15.7 transformer construction diagram................................................................... 42 15.8 winding instructions.......................................................................................... 43 15.8.1 shield foil assembly ..................................................................................... 44 secondary foil assembly......................................................................................... 44 15.8.3 design notes................................................................................................. 44 15.9 ep13 115 v ac transformer spreadsheets ........................................................ 45 15.9.1 115 v ac , 60 w peak load ............................................................................. 45 15.9.2 115 v ac , 45 w steady state load................................................................. 48 15.10 list of included parts for 230 vac-115 vac conversion ................................. 51 15.11 ep13 230 vac-115 vac conversion instructions ............................................ 51 15.11.1 required tools and supplies..................................................................... 51 15.11.2 conversion instructions ............................................................................. 51 16 appendix b miscellaneous custom parts ................................................................ 52 16.1 secondary heat sink ........................................................................................ 52 17 revision history ....................................................................................................... 53 EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 4 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 1 introduction this document is an engineering report describing a 230 v ac input, 5-output flyback supply utilizing topswitch ? -gx (top246y). the supply is rated for 43 w continuous output power, with 57 w of peak power capability for starting a disk drive. the design is optimized for high-end set-top box applications, but is easily adapted for other multiple output uses such as vcrs, dvd players, cable modems, and direct satellite receivers. the design kit includes a component kit and instructions for converting the supply to 115 v ac input operation. this document contains the power supply specification, schematic, and bill of materials, transformer documentation, printed circuit layout, and performance data. 6.875? 2.56? 1.56? figure 1 - ep13 populated circuit board. figure 2 - ep13 230 vac input to 115 vac input retrofit kit. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 5 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 2 power supply specification description symbol min typ max units comment input voltage v in 180 230 265 v ac 2 wire ? no p.e. frequency f line 47 50/60 64 hz no-load input power (230 v ac )0.75w output output voltage 1 v out1 3.14 3.30 3.46 v 5% output ripple voltage 1 v ripple1 33 mv 20 mhz bandwidth output current 1 i out1 1.0 3.00 3.00 a output voltage 2 v out2 4.75 5.00 5.25 v 5% output ripple voltage 2 v ripple2 50 mv 20 mhz bandwidth output current 2 i out2 1.00 3.20 3.20 a output voltage 3 v out3 11.16 12.0 12.84 v 7% output ripple voltage 3 v ripple3 120 mv 20 mhz bandwidth output current 3 i out3 0.30 0.60 1.8 * a * peak, 10 s max, thermally limited output voltage 4 v out4 16.74 18.00 19.26 v 7% output ripple voltage 4 v ripple4 180 mv 20 mhz bandwidth output current 4 i out4 0.5 - 0.5 a output voltage 5 v out5 29.7 33 36.3 v 10% output ripple voltage 5 v ripple5 200 mv 20 mhz bandwidth output current 5 i out5 0.01 - 0.03 a total output power continuous output power p out 43 w peak output power p out _ peak 57 w efficiency 75 % measured at p out (43 w), 25 o c environmental conducted emi meets cispr22b / en55022b safety designed to meet iec950, ul1950 class ii surge 4 kv 1.2/50 s surge, iec 1000-4-5, 12 ? series impedance, differential and common mode surge 4 kv 100 khz ring wave, 500 a short circuit current, differential and common mode ambient temperature t amb 050 o c free convection, sea level EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 6 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 3 schematic figure 3 - ep13 schematic. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 7 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 4 circuit description the ep13 is a five-output flyback power supply using the top246y integrated circuit. the circuit shown in figure 3 provides 43 w continuous power, with peak capability of 57 w (thermally limited). input voltage range is 180-265 v ac . ac input power is rectified and filtered by d1-4 and c2 to provide a high voltage dc bus, which is applied to the primary of transformer t1. the top246y drain pin drives the other side of the transformer primary. components d5, vr1, r2 and c5 clamp the drain voltage leakage inductance spike to below the 700 v maximum rating of the topswitch . the topswitch-gx family provides several new features, as well as extended specifications. the ep13 power supply is designed to take advantage of several of these features. resistor r1 connected to the line sense pin (l) of topswitch-gx u1 is used to implement the built-in line voltage feed forward and overvoltage protection features. the line feed forward feature modulates the control circuit of the topswitch-gx with the ac line frequency ripple component of the input dc, reducing the line frequency ripple at the output of the supply. this simplifies the design of the power supply control loop by reducing the amount of control loop gain required at the line ripple frequency in order to meet output ripple specifications. the overvoltage feature shuts down the power supply if the rectified dc bus voltage exceeds approximately 450 v, set by the value of r1. the supply resumes operation when the bus voltage falls again below the overvoltage threshold value. this feature allows the supply to withstand severe line transients or extended surge conditions without damage. this is an attractive feature for products designed for markets with poor power quality. resistor r4 connects to the external current limit pin (x) of u1 and is used to externally program the device current limit to just above the peak primary current of the supply at maximum peak load, minimum line voltage. this allows the transformer to be better optimized for the chosen operating conditions, while at the same time avoiding transformer core saturation during start-up or overload conditions. transformer optimization choices can include using a smaller core (less expensive transformer), fewer primary turns (less leakage inductance), or higher primary inductance (more continuous operation, less topswitch dissipation). the ep13 transformer design does not take full advantage of the flexibility offered by the topswitch-gx due to secondary volts per turn required to minimize voltage error between 3.3 v and 5 v outputs. the secondary turns were deliberately chosen to optimize output voltage centering with the fewest possible number of turns. the reflected EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 8 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com voltage at the primary was fixed at 100 v to optimize output cross regulation, thus fixing the number of primary turns. a design with fewer output voltages can take better advantage of the design flexibility offered by the topswitch-gx family. d6 and c3 provide a dc voltage of approximately 12 v to power the top246y. a relatively large value of c3 (1 f) is used to provide bias voltage ride-through during severe output load transients. capacitor c4 filters the internal bias supply of the topswitch-gx , providing the necessary peak currents to drive the gate of its internal high-voltage mosfet. capacitor c4 also determines the topswitch-gx auto-restart frequency, and along with resistor r3, helps to compensate the power supply control loop. transformer t1 utilizes a nine section slotted bobbin designed for an automated production environment. primary and secondary windings are applied in alternate bobbin slots using ordinary magnet wire. the slots provide the necessary safety isolation and creepage distance between the primary and secondary windings without the need for additional insulation of any kind. the large number of winding slots provides sufficient interleaving of primary and secondary windings to reduce the leakage inductance to a tolerable value, while the open construction of the transformer reduces winding temperature rise, allowing use of relatively fine wire, further facilitating automatic winding. diodes d7, 8, 9, 10 and 11, along with capacitors c7, 9, 11, 13, 14, 16 and 17 are used to rectify and filter the five output secondary windings of t1. two techniques are used to properly center the output voltages of the supply and to improve cross regulation between outputs. an ultrafast rectifier is used for d10 (5 v output rectifier) instead of a schottky rectifier. the extra voltage drop of the ultrafast rectifier centers the 5 v output at precisely 5 v. also, the 12 v, 18 v and 30 v secondary windings are stacked on the cathode side of the 5 v output rectifier (dc stacking) rather than the anode side (ac stacking). this means that the current for these outputs passes through the 5 v output rectifier (d10) as well as their respective output rectifiers (d7, 8, and 9). this increases the dissipation in d10, but has two beneficial effects. first, the extra voltage drop imposed by d10 precisely centers the 12 v output. also, since the current for the 12 v, 18 v and 30 v outputs passes through d10 and its connecting printed circuit traces, variations in the current from these outputs will modulate the voltage drop across d10 to a certain extent. this change is passed on to the 5 v output, causing the output control loop to change the duty cycle to compensate. this indirect feedback improves the cross regulation of these outputs. inductors l2, 3, 4, 5 and 6 are used along with capacitors c8, 10, 12, 15 and 18 to provide high frequency filtering for the five outputs of the supply. these filters greatly reduce the switching frequency ripple and high frequency spike noise at the outputs of the supply. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 9 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com a voltage divider consisting of resistors r10, 11 and 13 monitors the voltage on the 5 v and 3.3 v outputs. the resistor values are weighted so that the voltage feedback loop is controlled mostly by the 5 v output, with some contribution from the 3.3 v output. sharing the voltage regulation control between the two outputs in this manner improves the cross regulation for the 3.3 v output at the expense of a slight change in the regulation of the 5 v output. the voltage from r10, 11 and 13 is applied to the reference pin of shunt regulator u3. these resistor values and the reference voltage of u3 are used to set the output voltages of the supply. resistor r7 is used to set the overall gain of the supply control loop, while r8 provides bias current for u3. r9 and c19 provide frequency compensation for u3 to help stabilize the power supply control loop. capacitor c20 is used to provide open loop feedback through optocoupler u2 during start-up, which in conjunction with the built-in soft start-up feature of topswitch-gx , completely controls the start-up drain current profile, preventing transformer saturation and output overshoot. optocoupler u2 applies the feedback signal from u3 to the control pin of u1. resistor r15 and capacitor c24 form a snubber across d10 that reduces the reverse recovery transient from this diode, improving emi performance. inductor l7 is a ferrite bead placed in series with the 12 v, 18 v and 30 v output windings of t1. this bead acts as a small saturable reactor to improve the centering and cross regulation of these outputs. r6 provides a small amount of pre-filtering for the 30 v output, and is used to help prevent peak charging of this output due to leakage spikes. c1, l1 and c6 provide common-mode and differential mode emi filtering for the power supply. fuse f1 protects against gross circuit faults. varistor rv1 is used to clamp differential mode line transients. thermistor rt1 reduces the initial current surge when ac power is first applied to the circuit. EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 10 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 5 pcb layout figure 4 - ep13 printed circuit layout. (approximately 1:1 scale) 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 11 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 6 bill of materials ep13 set top supply, 230 vac slot wound xfmr 1/25/01 bill of materials item qty reference description p/n manufacturer 11c1 0.22 f 250 v, x2 306 20224 philips 21c2 68 f, 400 v eco-s2gp680aa panasonic 31c3 1 f, 50 v nhg eca-1hhg010 panasonic 41c4 47 f 16 v nhg eca-1chg470 panasonic 5 1 c5 1 nf, 1 kv eck-d3a102kbn panasonic 61c6 2.2 f, y1 440ld22 cera-mite 71c7 47 f, 50 v nhg eca-1hhgg470 panasonic 81c8 10 f, 50 v nhg eca-1hhg100 panasonic 9 1 c9 330 f, 25 v hfq eca-1efq331 panasonic 10 2 c10, 12 100 f, 25 v nhg eca-1ehg101 panasonic 11 1 c11 390 f, 35 v hfq eca-1vfq391 panasonic 12 4 c13, 14,16,17 1000 f, 25 v hfq eca-1efq102 panasonic 13 2 c15, 18 220 f,16 v nhg eca-1chg221 panasonic 14 2 c19, 23 0.1 f, 50 v k104m15z5uf5th5 beyerschlag /centralab 15 1 c20 22 f, 50 v nhg eca-1hhg220 panasonic 16 1 c24 1 nf, 50 v k102k15x7rf5tl2 beyerschlag /centralab 17 4 d1-4 1 a, 1000 v 1n4007 18 1 d5 1 a, 600 v, 200 nsec 1n4937 general semiconductor 19 1 d6 diode, 75 v 1n4148 20 1 d7 1 a, 200 v, 50 nsec uf4003 general semiconductor 21 2 d8, 9 3 a, 200 v, 50 nsec uf5402 general semiconductor 22 1 d10 20 a, 200 v, 35 nsec byv32-200 philips 23 1 d11 10 a, 45 v schottky mbr1045 general semiconductor 24 1 f1 fuse, 250 vac 3.15 a 372-1315 wickman 25 1 l1 20 mh, 0.8 a elf-18n008a panasonic 26 4 l2-5 3.3 uh, 622-ly-3r3m toko 27 1 l6 33 uh, 190 ma 78f330j j.w. miller 28 1 l7 ferrite bead 2643022401 fair-rite 29 1 r1 2 m, 1/2 w, 5% 30 1 r2 68 k ? , 2 w, 5% metal oxide 31 1 r3 6.8 ? , 1/4 w, 5% 32 1 r4 9.09 k ? , 1 %, rn55 33 2 r6, 15 10 ? , 1/4 w, 5% 34 1 r7 150 ? , 1/4 w, 5% 35 1 r8 1 k ? , 1/4 w, 5% 36 1 r9 3.3 k ? , 1/4 w, 5% 37 1 r10 9.53 k ? , 1%, rn55 38 1 r11 10 k ? , 1%, rn55 39 1 r13 15 k ? , 1%, rn55 40 1 r14 2.7 k ? , 1/2 w, 5% EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 12 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 41 1 t1 xfmr, custom slotted bobbin orega 42 1 u1 top246y power integrations 43 1 u2 optocoupler, graded ctr ltv817a liteon 44 1 u3 shunt regulator, 1% tl431aclp ti 45 1 rv1 varistor, 275 vac, 14 mm 46 1 vr1 tvs, 200 v, 600 w p6ke200 general semiconductor 47 1 rt1 thermistor, 10 ohm 1.7 a kc012l keystone 48 1 j1 3 pin, 0.156 ctr* 26-60-2030 molex 49 1 j2 14 pin, 0.156 ctr. 26-60-2140 molex 50 1 hs1 heat sink, to-220, 1.5? ht. 531102n02500 aavid 51 1 hs2 heat sink custom 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 13 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7 transformer specification figure 5 - ep13 multiple slot transformer. 7.1 electrical specifications electrical strength 1 minute, 60 hz, from pins 1-9 to pins 10-18 3000 vac primary inductance pins 1-5 with pins 3-4 shorted together, all other windings open, 130 khz measurement frequency 487 h +/-10% resonant frequency pins 1-5 with pins 3-4 shorted together, all other windings open 2 mhz minimum primary leakage inductance pins 1-5 with pins 3-4 shorted together, pins 10- 18 shorted together, 130 khz measurement frequency 15 h maximum 7.2 materials item description [1] orega smt18 core/bobbin set, gap core for a l of 180 nh/t 2 [2] magnet wire, solderable double coated 0.25 mm/30 awg [3] epoxy glue EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 14 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 7.3 winding instructions slot # start pin turns wire size finish pin slot 1 ? start pin 5 26t 0.25 mm finish pin 3 slot 2 ? start pin 11 1t 0.25 mm finish pin 14 start pin 14 2t 0.25 mm finish pin 12 start pin 16 4t 0.25 mm finish pin 10 start pin 17 3t 0.25 mm finish pin 16 start pin 18 6t 0.25 mm finish pin 17 slot 3 ? start pin 3 26t 0.25 mm finish pin 1 start pin 8 7t 0.25 mm finish pin 9 slot 4 ? start pin 11 1t 0.25 mm finish pin 14 start pin 14 2t 0.25 mm finish pin 12 start pin 14 2t 0.25 mm finish pin 12 slot 5 ? start pin 5 26t 0.25 mm finish pin 4 slot 6 ? start pin 11 1t 0.25mm finish pin 15 start pin 15 2t 0.25mm finish pin 13 start pin 15 2t 0.25 mm finish pin 13 start pin 16 4t 0.25 mm finish pin 10 slot 7 ? start pin 4 26t 0.25 mm finish pin 1 slot 8 ? start pin 11 1t 0.25 mm finish pin 15 start pin 15 2t 0.25 mm finish pin 13 start pin 16 4t 0.25 mm finish pin 10 start pin 17 3t 0.25 mm finish pin 16 start pin 18 6t 0.25 mm finish pin 17 slot 9 ? start pin 5 26t 0.25 mm finish pin 4 7.4 transformer sources for information on the vendors used to source the transformers used on this board, please visit the power integrations' web site at the url below and select ?engineering prototype boards? http://www.powerint.com/componentsuppliers.htm 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 15 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8 transformer spreadsheets 8.1 230 v ac , 60 w peak load acdc_topgx_rev1.1_040401 copyright power integrations inc. 2000 input info output unit top_gx_040401.xls: topswitch-gx continuous/discontinuous flyback transformer design spreadsheet enter application variables customer vacmin 180 volts minimum ac input voltage vacmax 265 volts maximum ac input voltage fl 50 hertz ac mains frequency vo 3.3 volts output voltage po 60 watts output power n 0.7 efficiency estimate z 0.5 loss allocation factor vb 12 volts bias voltage tc 3 mseconds bridge rectifier conduction time estimate cin 68 farads input filter capacitor enter topswitch-gx variables top-gx top246 universal 115 doubled/230 v chosen device top246 power out 90 w 150 w ki 0.8 external ilimit reduction factor (ki=1.0 for default ilimit, ki <1.0 for lower ilimit) ilimitmin 1.944 amps use 1% resistor in setting external ilimit ilimitmax 2.376 amps use 1% resistor in setting external ilimit frequency - (f)=130 khz, (h)=65 khz f full (f) frequency option - 130 khz fs 130000 1.30e+05 hertz topswitch-gx switching frequency: choose between 130 khz and 65 khz fsmin 1.24e+05 hertz topswitch-gx minimum switching frequency fsmax 1.40e+05 hertz topswitch-gx maximum switching frequency vor 99 volts reflected output voltage vds 10 volts topswitch on-state drain to source voltage vd 0.5 volts output winding diode forward voltage drop vdb 0.7 volts bias winding diode forward voltage drop kp 0.60 ripple to peak current ratio (0.4 < krp < 1.0 : 1.0< kdp<6.0) enter transformer core/construction variables core type eer28l core eer28l p/n: pc40eer28l-z bobbin eer28l_bobbin p/n: beer-28l-1112cph ae 0.814 cm^2 core effective cross sectional area le 7.55 cm core effective path length al 2520 nh/t^2 ungapped core effective inductance bw 21.8 mm bobbin physical winding width m0mm safety margin width (half the primary to secondary creepage distance) l 3.3 number of primary layers ns 2 number of secondary turns EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 16 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com dc input voltage parameters vmin 217 volts minimum dc input voltage vmax 375 volts maximum dc input voltage current waveform shape parameters dmax 0.32 maximum duty cycle iavg 0.39 amps average primary current ip 1.74 amps peak primary current ir 1.05 amps primary ripple current irms 0.72 amps primary rms current transformer primary design parameters lp 460 henries primary inductance np 52 primary winding number of turns nb 7 bias winding number of turns alg 169 nh/t^2 gapped core effective inductance bm 1891 gauss maximum flux density at po, vmin (bm<3000) bp 2577 gauss peak flux density (bp<4200) bac 567 gauss ac flux density for core loss curves (0.5 x peak to peak) ur 1860 relative permeability of ungapped core lg 0.56 mm gap length (lg > 0.1 mm) bwe 71.94 mm effective bobbin width od 1.38 mm maximum primary wire diameter including insulation ins 0.09 mm estimated total insulation thickness (= 2 * film thickness) dia 1.29 mm bare conductor diameter awg 17 awg primary wire gauge (rounded to next smaller standard awg value) cm 2048 cmils bare conductor effective area in circular mils cma warning 2864 cmils/amp !!!!!!!!!! decrease cma> (decrease l (primary layers), increase ns, smaller core) transformer secondary design parameters (single output / single output equivalent) lumped parameters isp 45.43 amps peak secondary current isrms 26.95 amps secondary rms current io 18.18 amps power supply output current iripple 19.89 amps output capacitor rms ripple current cms 5390 cmils secondary bare conductor minimum circular mils awgs 12 awg secondary wire gauge (rounded up to next larger standard awg value) dias 2.05 mm secondary minimum bare conductor diameter ods 10.90 mm secondary maximum outside diameter for triple insulated wire inss 4.42 mm maximum secondary insulation wall thickness voltage stress parameters vdrain 603 volts maximum drain voltage estimate (includes effect of leakage inductance) pivs 18 volts output rectifier maximum peak inverse voltage pivb 60 volts bias rectifier maximum peak inverse voltage 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 17 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com transformer secondary design parameters (multiple outputs) 1st output vo1 5.0 volts output voltage io1 3.200 amps output dc current po1 16.00 watts output power vd1 0.7 volts output diode forward voltage drop ns1 3.00 output winding number of turns isrms1 4.743 amps output winding rms current iripple1 3.50 amps output capacitor rms ripple current pivs1 27 volts output rectifier maximum peak inverse voltage cms1 949 cmils output winding bare conductor minimum circular mils awgs1 20 awg wire gauge (rounded up to next larger standard awg value) dias1 0.81 mm minimum bare conductor diameter ods1 7.27 mm maximum outside diameter for triple insulated wire 2nd output vo2 12.0 volts output voltage io2 0.600 amps output dc current po2 7.20 watts output power vd2 1.4 volts output diode forward voltage drop ns2 7.05 output winding number of turns isrms2 0.889 amps output winding rms current iripple2 0.66 amps output capacitor rms ripple current pivs2 63 volts output rectifier maximum peak inverse voltage cms2 178 cmils output winding bare conductor minimum circular mils awgs2 27 awg wire gauge (rounded up to next larger standard awg value) dias2 0.36 mm minimum bare conductor diameter ods2 3.09 mm maximum outside diameter for triple insulated wire 3rd output vo3 18.0 volts output voltage io3 0.500 amps output dc current po3 9.00 watts output power vd3 1.4 volts output diode forward voltage drop ns3 10.21 output winding number of turns isrms3 0.741 amps output winding rms current iripple3 0.55 amps output capacitor rms ripple current pivs3 91 volts output rectifier maximum peak inverse voltage cms3 148 cmils output winding bare conductor minimum circular mils awgs3 28 awg wire gauge (rounded up to next larger standard awg value) dias3 0.32 mm minimum bare conductor diameter ods3 2.14 mm maximum outside diameter for triple insulated wire EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 18 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 8.2 230 v ac , 45 w steady state load acdc_topgx_rev1.1_040401 copyright power integrations inc. 2000 input info output unit top_gx_040401.xls: topswitch-gx continuous/discontinuous flyback transformer design spreadsheet enter application variables customer vacmin 180 volts minimum ac input voltage vacmax 265 volts maximum ac input voltage fl 50 hertz ac mains frequency vo 3.3 volts output voltage po 45 watts output power n 0.75 efficiency estimate z 0.5 loss allocation factor vb 12 volts bias voltage tc 3 mseconds bridge rectifier conduction time estimate cin 68 farads input filter capacitor enter topswitch-gx variables top-gx top246 universal 115 doubled/230 v chosen device top246 power out 90 w 150 w ki 0.8 external ilimit reduction factor (ki=1.0 for default ilimit, ki <1.0 for lower ilimit) ilimitmin 1.944 amps use 1% resistor in setting external ilimit ilimitmax 2.376 amps use 1% resistor in setting external ilimit frequency - (f)=130 khz, (h)=65 khz f full (f) frequency option - 130 khz fs 130000 1.30e+05 hertz topswitch-gx switching frequency: choose between 130 khz and 65 khz fsmin 1.24e+05 hertz topswitch-gx minimum switching frequency fsmax 1.40e+05 hertz topswitch-gx maximum switching frequency vor 99 volts reflected output voltage vds 10 volts topswitch on-state drain to source voltage vd 0.5 volts output winding diode forward voltage drop vdb 0.7 volts bias winding diode forward voltage drop kp 0.79 ripple to peak current ratio (0.4 < krp < 1.0 : 1.0< kdp<6.0) enter transformer core/construction variables core type eer28l core eer28l p/n: pc40eer28l-z bobbin eer28l_bobbin p/n: beer-28l-1112cph ae 0.814 cm^2 core effective cross sectional area le 7.55 cm core effective path length al 2520 nh/t^2 ungapped core effective inductance bw 21.8 mm bobbin physical winding width m0mm safety margin width (half the primary to secondary creepage distance) l 1 number of primary layers ns 2 number of secondary turns dc input voltage parameters vmin 229 volts minimum dc input voltage vmax 375 volts maximum dc input voltage 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 19 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com current waveform shape parameters dmax 0.31 maximum duty cycle iavg 0.26 amps average primary current ip 1.39 amps peak primary current ir 1.10 amps primary ripple current irms 0.50 amps primary rms current transformer primary design parameters lp 458 henries primary inductance np 52 primary winding number of turns nb 7 bias winding number of turns alg 169 nh/t^2 gapped core effective inductance bm 1501 gauss maximum flux density at po, vmin (bm<3000) bp 2565 gauss peak flux density (bp<4200) bac 593 gauss ac flux density for core loss curves (0.5 x peak to peak) ur 1860 relative permeability of ungapped core lg 0.57 mm gap length (lg > 0.1 mm) bwe 21.8 mm effective bobbin width od 0.42 mm maximum primary wire diameter including insulation ins 0.06 mm estimated total insulation thickness (= 2 * film thickness) dia 0.36 mm bare conductor diameter awg 28 awg primary wire gauge (rounded to next smaller standard awg value) cm 161 cmils bare conductor effective area in circular mils cma 321 cmils/amp primary winding current capacity (200 < cma < 500) transformer secondary design parameters (single output / single output equivalent) lumped parameters isp 36.24 amps peak secondary current isrms 19.45 amps secondary rms current io 13.64 amps power supply output current iripple 13.86 amps output capacitor rms ripple current cms 3889 cmils secondary bare conductor minimum circular mils awgs 14 awg secondary wire gauge (rounded up to next larger standard awg value) dias 1.63 mm secondary minimum bare conductor diameter ods 10.90 mm secondary maximum outside diameter for triple insulated wire inss 4.64 mm maximum secondary insulation wall thickness voltage stress parameters vdrain 603 volts maximum drain voltage estimate (includes effect of leakage inductance) pivs 18 volts output rectifier maximum peak inverse voltage pivb 60 volts bias rectifier maximum peak inverse voltage EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 20 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com transformer secondary design parameters (multiple outputs) 1st output vo1 5.0 volts output voltage io1 3.200 amps output dc current po1 16.00 watts output power vd1 0.7 volts output diode forward voltage drop ns1 3.00 output winding number of turns isrms1 4.563 amps output winding rms current iripple1 3.25 amps output capacitor rms ripple current pivs1 27 volts output rectifier maximum peak inverse voltage cms1 913 cmils output winding bare conductor minimum circular mils awgs1 20 awg wire gauge (rounded up to next larger standard awg value) dias1 0.81 mm minimum bare conductor diameter ods1 7.27 mm maximum outside diameter for triple insulated wire 2nd output vo2 12.0 volts output voltage io2 0.600 amps output dc current po2 7.20 watts output power vd2 1.4 volts output diode forward voltage drop ns2 7.05 output winding number of turns isrms2 0.856 amps output winding rms current iripple2 0.61 amps output capacitor rms ripple current pivs2 63 volts output rectifier maximum peak inverse voltage cms2 171 cmils output winding bare conductor minimum circular mils awgs2 27 awg wire gauge (rounded up to next larger standard awg value) dias2 0.36 mm minimum bare conductor diameter ods2 3.09 mm maximum outside diameter for triple insulated wire 3rd output vo3 18.0 volts output voltage io3 0.500 amps output dc current po3 9.00 watts output power vd3 1.4 volts output diode forward voltage drop ns3 10.21 output winding number of turns isrms3 0.713 amps output winding rms current iripple3 0.51 amps output capacitor rms ripple current pivs3 91 volts output rectifier maximum peak inverse voltage cms3 143 cmils output winding bare conductor minimum circular mils awgs3 28 awg wire gauge (rounded up to next larger standard awg value) dias3 0.32 mm minimum bare conductor diameter ods3 2.14 mm maximum outside diameter for triple insulated wire 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 21 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9 performance data all measurements performed at room temperature, 60 hz input frequency. 9.1 efficiency efficiency vs. vin 70% 71% 72% 73% 74% 75% 76% 77% 78% 79% 80% 160 180 200 220 240 260 280 ac input voltage efficiency (%) max continuous load max peak load figure 6 - efficiency vs. input voltage, full load, room temperature, 60 hz. 9.2 no-load input power zero load input power vs. line voltage 0.5 0.55 0.6 0.65 0.7 0.75 0.8 160 180 200 220 240 260 280 ac input voltage (v ac ) input power (w) figure 7 - zero load input power vs. input line voltage room temperature, 60 hz. EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 22 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.3 regulation 9.3.1 maximum load all outputs line regulation, full load 98% 99% 100% 101% 102% 103% 104% 105% 160 180 200 220 240 260 280 ac input voltage (v ac ) regulation (% of absolute voltage). 3.3v 5v 12v 18v 30v figure 8 - line regulation, maximum continuous load 9.3.2 peak load all outputs line regulation - peak load (3.3 v @ 3a, 5 v @ 3.2 a, 12 v @ 1.8 a, 18 v @ 0.5 a, 30 v @ 30 ma) 98% 99% 100% 101% 102% 103% 104% 160 180 200 220 240 260 280 ac input voltage regulation (% of absolute voltage) 3.3v 5v 12v 18v 30v figure 9 - line regulation, peak load condition 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 23 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.3.3 3.3 v min. load, 12 v peak, other outputs fully loaded line regulation (3.3 v @ 1 a, 5 v @ 3.2 a, 12 v @ 1.8 a, 18v @ 0.5 a, 30 v @ 30 ma) 95.0% 97.0% 99.0% 101.0% 103.0% 105.0% 160 180 200 220 240 260 280 ac input voltage (v ac ) regulation (% of absolute voltage). 3.3v 5v 12v 18v 30v figure 10 - line regulation, 3.3 v @ 1 a, 12 v @ 1.8 a, all other outputs maximum steady state load 9.3.4 12 v min. load, other outputs at maximum load condition line regulation - peak load condition ( 3.3 v @ 3 a, 5 v @ 3.2 a, 12 v @ 0.3 a, 18 v @ 0.5 a, 30 v @ 30 ma) 99% 100% 101% 102% 103% 104% 105% 106% 160 180 200 220 240 260 280 ac input voltage regulation (% of absolute voltage). 3.3v 5v 12v 18v 30v figure 11 - line regulation, 12 v min, and all other outputs maximum load EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 24 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 9.3.5 12 v peak load, 30 v min. load, other outputs at max. load line regulation - peak load (3.3 v @ 3 a, 5 v @ 3.2 a, 12 v @ 1.8 a, 18 v @ 0.6 a, 30 v @ 10 ma) 98% 100% 102% 104% 106% 108% 110% 160 180 200 220 240 260 280 ac input voltage (v ac ) regulation (% of absolute voltage). 3.3v 5v 12v 18v 30v figure 12 - line regulation ? 12 v peak, 30 v min. load condition 9.3.6 5 v and 3.3 v min load, all other outputs maximum line regulation 5v @ 1a, 3.3 v @ 1 a, 12 v @ 0.6 a, 18 v @ 0.5 a, 30 v @ 0.03 a 95% 96% 97% 98% 99% 100% 101% 102% 103% 104% 160 180 200 220 240 260 280 ac input voltage regualtion (% of absolute output voltage). 3.3v 5v 12v 18v 30v figure 13 - line regulation ? 5 v and 3.3 v minimum, other output maximum load 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 25 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 10 thermal performance temperature item 180 vac 230 vac 180 vac 230 vac ambient 30.2 c 31.1 c 50.9 c 52 c balun (l1) 41.1 c 37.8 c 59.7 c 55.7 c thermistor (rt1) 78.9 c 71.3 c 99.3 c 90.1 c snubber resistor (r2) 69.4 c 69.3 c 86.4 c 85.6 c clamp zener (vr1) 65.9 c 63.4 c 85.0 c 81.2 c topswitch (u1) 58.6 c 59.3 c 81 c 79.7 c transformer (t1) 71.2 c 72.6 c 94.8 c 93.7 c 18v rectifier (d8) 67.8 c 68.8 c 87.3 c 87.5 c 12v rectifier (d9) 74.2 c 75.1 c 94.0 c 93.8 c 5v rectifier (d10) 80.3 c 81.8 c 102.7 c 102.5 c 3.3v rectifier (d11) 73.7 c 75 c 96.1 c 96.0 c figure 14 - ep13 thermal performance figure 15 - infrared thermograph of ep13, 180 v ac input, maximum continuous load, 22 c ambient. (board was sprayed black to give an accurate emissivity figure) EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 26 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11 waveforms 11.1 drain voltage and current, normal operation figure 16 - 180 v ac - upper: i drain , 0.5 a / div, lower: v drain , 200 v / div, 2 s / div figure 17 - 265 vac, full load - upper: i drain , 0.5 a / div, lower: v drain , 200 v / div, 2 s / div 11.2 output voltage start-up profile figure 18 - start-up profile, 3.3 v, 5 v and 12 v outputs. 2 v & 5 ms / div. figure 19 - start-up profile, 5 v, 18 v and 30 v outputs. 2 v & 5 ms / div. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 27 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.3 drain voltage and current start-up profile figure 20 - 180 v ac input and maximum load. upper: i drain , 0.5 a / div. lower: v drain , 100 v & 2 ms / div. figure 21 - 265 v ac input and maximum load. upper: i drain , 0.5 a / div. lower: v drain , 100 v & 2 ms / div. EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 28 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.4 load transient response (75% to 100% load step) in the figures shown below, signal averaging was used to better enable viewing the load transient response. the oscilloscope was triggered using the load current step as a trigger source. since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response. figure 22 - 5 v and 3.3 v transient response. 75-100-75% load step 5 v output. upper: 5 v, 100 mv / div. middle: 3.3 v, 100 mv / div. bottom: 5 v output current, 1 a / div. 500 s / div. figure 23 - 12, 18 and 30 v transient response. 75-100-75% load step 5 v output. upper: 30 v, 200 mv / div. middle1: 18 v, 200 mv / div. middle2: 12 v, 200 mv / div. bottom: 5 v output current, 1 a / div. 2 ms / div. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 29 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5 output ripple measurements 11.5.1 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 figure 24 and figure 25. 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/50 v aluminum electrolytic. the aluminum electrolytic type capacitor is polarized, so proper polarity across dc outputs must be maintained (see below). figure 24 - oscilloscope probe prepared for ripple measurement. (end cap and ground lead removed) figure 25 - oscilloscope probe with probe master 5125ba bnc adapter. (modified with wires for probe ground for ripple measurement, and two parallel decoupling capacitors added) probe ground probe tip EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 30 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5.2 measurement results at 180 v ac figure 26 - 3.3 v ripple, 180 v ac , full load. 2 ms, 20 mv / div figure 27 - 5 v ripple, 180 v ac , full load. 2 ms, 20 mv / div figure 28 - 12 v ripple, 180 v ac , full load. 2ms, 20 mv / div figure 29 - 18 v ripple, 180 v ac , full load. 2 ms, 20 mv / div figure 30 - 33 v ripple, 180 vac, full load. 2 ms, 20 mv / div 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 31 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 11.5.3 measurement results at 230 v ac figure 31 - 3.3 v ripple, 230 v ac , full load. 2 ms, 20 mv / div figure 32 - 5 v ripple, 230 v ac , full load. 2 ms, 20 mv / div figure 33 - 12 v ripple, 230 v ac , full load. 2 ms, 20 mv / div figure 34 - 18 v ripple, 230 v ac , full load. 2 ms, 20 mv / div figure 35 - 18 v ripple, 230 vac, full load. 2 ms, 20 mv / div EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 32 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 12 control loop measurements 12.1 180 v ac maximum load 0 db gain 45 phase margin figure 36 - gain-phase plot, 180 vac, maximum steady state load vertical scale: gain = 10 db/div, phase = 30 /div. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 33 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 12.2 230 v ac maximum load 0 db gain 50 phase mar g in figure 37 - gain-phase plot, 230 v ac , maximum steady state load vertical scale: gain = 10 db/div, phase = 30 /div. EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 34 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 12.3 265 v ac maximum load 0 db gain 63 phase margin figure 38 - gain-phase plot, 265 v ac , maximum steady state load vertical scale: gain = 10 db/div, phase = 30 /div. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 35 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 13 conducted emi qp limit line av limit line quasi-peak scan average scan figure 39 - conducted emi, maximum steady state load, 230 v ac , 60 hz, and en55022 b limits. 14 ac surge and 100 khz ring wave immunity four series of line transient tests were performed on the ep13 to determine the level of immunity attainable for the basic board. testing was performed using a keytek emc pro surge generator. the input voltage for the supply under test was 230 vac, and the supply was loaded to the maximum continuous output power using resistive loads on each output. an led was used to monitor the presence of output voltage and to detect output interruptions. test for each series was terminated upon non-destructive interruption of output voltage, arcing, or non-recoverable interruption of output voltage. a test failure was defined as a non-recoverable interruption of output voltage requiring supply repair or recycling of input ac voltage. EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 36 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 14.1 common mode surge, 1.2/50 sec surge voltage phase angle ( ) generator impedance number of strikes test result 1 kv 0 12 ohms 10 pass 1 kv 90 12 ohms 10 pass 1 kv 270 12 ohms 10 pass 1.5 kv 0 12 ohms 10 pass 1.5 kv 90 12 ohms 10 pass 1.5 kv 270 12 ohms 10 pass 2 kv 0 12 ohms 10 pass 2 kv 90 12 ohms 10 pass 2 kv 270 12 ohms 10 pass 2.5 kv 0 12 ohms 10 pass 2.5 kv 90 12 ohms 10 pass 2.5 kv 270 12 ohms 10 pass 3 kv 0 12 ohms 10 pass 3 kv 90 12 ohms 10 pass 3 kv 270 12 ohms 10 pass 3.5 kv 0 12 ohms 10 pass 3.5 kv 90 12 ohms 10 pass 3.5 kv 270 12 ohms 10 pass 4 kv 0 12 ohms 10 pass 4 kv 90 12 ohms 10 pass 4 kv 270 12 ohms 1 pass (board arcing, supply still operational) 14.2 differential mode surge, 1.2/50 sec surge voltage phase angle ( ) generator impedance number of strikes test result 1 kv 0 12 ohms 10 pass 1 kv 90 12 ohms 10 pass 1 kv 270 12 ohms 10 pass 1.5 kv 0 12 ohms 10 pass 1.5 kv 90 12 ohms 10 pass 1.5 kv 270 12 ohms 10 pass 2 kv 0 12 ohms 10 pass 2 kv 90 12 ohms 10 pass 2 kv 270 12 ohms 10 pass 2.5 kv 0 12 ohms 10 pass 2.5 kv 90 12 ohms 10 pass 2.5 kv 270 12 ohms 10 pass 3 kv 0 12 ohms 10 pass 3 kv 90 12 ohms 10 pass 3 kv 270 12 ohms 10 pass 3.5 kv 0 12 ohms 10 pass 3.5 kv 90 12 ohms 10 pass 3.5 kv 270 12 ohms 10 pass 4 kv 0 12 ohms 10 pass 4 kv 90 12 ohms 1 pass (output interruption, board still functional) 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 37 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 14.3 common mode, 100 khz ring wave surge voltage (kv) phase angle ( ) short circuit current number of strikes test result 1 kv 0 500 a 10 pass 1 kv 90 500 a 10 pass 1 kv 270 500 a 10 pass 2 kv 0 500 a 10 pass 2 kv 90 500 a 10 pass 2 kv 270 500 a 10 pass 3 kv 0 500 a 10 pass 3 kv 90 500 a 10 pass 3 kv 270 500 a 10 pass 4 kv 0 500 a 10 pass 4 kv 90 500 a 10 pass 4 kv 270 500 a 10 pass 4.5 kv 0 500 a 10 pass 4.5 kv 90 500 a 10 pass 4.5 kv 270 500 a 10 pass 5 kv 0 500 a 10 pass 5 kv 90 500 a 10 pass 5 kv 270 500 a 10 pass 5.5 kv 0 500 a 10 pass 5.5 kv 90 500 a 10 pass 5.5 kv 270 500 a 10 pass 6 kv 0 500 a 1 fail* * u1 failure 14.4 differential mode, 100 khz ring wave surge voltage phase angle ( ) short circuit current number of strikes test result 3 kv 0 500 a 10 pass 3 kv 90 500 a 10 pass 3 kv 270 500 a 10 pass 4 kv 0 500 a 10 pass 4 kv 90 500 a 10 pass 4 kv 270 500 a 10 pass 4.5 kv 0 500 a 10 pass 4.5 kv 90 500 a 10 pass 4.5 kv 270 500 a 10 pass 5 kv 0 500 a 10 pass 5 kv 90 500 a 10 pass 5 kv 270 500 a 10 pass 5.5 kv 0 500 a 10 pass 5.5 kv 90 500 a 10 pass 5.5 kv 270 500 a 10 pass 6 kv 0 500 a 10 pass 6 kv 0 500 a 10 pass 6 kv 0 500 a 10 pass EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 38 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15 appendix a ? ep13, 115 v ac version a kit of parts is included in the dak-13 to convert the ep13 supply from 230 v to 115 v operation. the ep13 printed circuit board is designed to accommodate these changes without modification, so that only a stuffing change is required. specification, schematic, and modification information for the ep13 115 v version are shown below. 15.1 115 vac option power supply specification description symbol min typ max units comment input voltage 85 132 vac 2 wire output output voltage 1 v out1 3.14 3.30 3.46 v +/-5% output ripple voltage 1 v ripple1 33 mv 20 mhz bw output current 1 i out 1.0 3.00 3.00 a output voltage 2 v out2 4.75 5.00 5.25 v +/-5% output ripple voltage 2 v ripple2 50 mv 20 mhz bw output current 2 i out 1.00 3.20 3.20 a output voltage 3 v out3 11.16 12.0 12.84 v +/-7% output ripple voltage 3 v ripple3 120 mv 20 mhz bw output current 3 i out 0.30 0.60 1.8* a *peak load, 10 sec max. output voltage 4 v out4 16.74 18.00 19.26 v +/-7% output ripple voltage 4 v ripple4 180 mv 20 mhz bw output current 4 i out 0.5 - 0.5 a output voltage 5 v out5 27 33 32.4 v +/-10% output ripple voltage 5 v ripple5 200 mv 20 mhz bw output current 5 i out 0.01 - 0.03 a total output power continuous output power p out _ total 43 w peak output power 57 efficiency 75% % @ maximum continuous load environmental conducted emi meets cispr22b/en55022b safety designed to meet iec950, ul1950 class ii ambient temperature 0 c 50 c o c free convection, sea level table 1 - ep13 115 v ac option specification 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 39 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.2 schematic for ep13 115 v ac -only version figure 40 - schematic for ep13 115 v ac only version EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 40 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.3 ep13 115 v ac version circuit description the circuit shown in the schematic of figure 38 is a 115 vac-only version of the ep13. several notable changes were made in the circuit to accommodate 115 vac-only operation. c2 is changed from 68 f, 400 v to 150 f, 200 v. rt1, d1-4, and l1 were changed to devices with higher current rating to accommodate the increased current draw at 115 vac. u1 is changed from a top246y to a top247y, which has a higher current rating. since the 115 vac-only supply runs at a higher primary peak and rms current, the secondary rms currents are correspondingly higher. to handle the increased secondary rms ripple current, the filter capacitors in the 5 v and 3.3 v outputs (c13-14 and c16- 17) are changed to devices with a higher ripple current rating. r12 and c21 have been added on the secondary voltage control to inject ac ripple information from the 12 v output into the control circuit. this ?ripple steering? circuit reduces the 12 v output ripple, especially at low ac input voltage. t1 is replaced with a conventional margin-wound erl28 transformer, since the multiple section transformer used in the 230 vac version of the ep13 cannot handle the higher primary and secondary currents present at lower input voltages. the 5 v and 3.3 v secondaries in this transformer are wound using copper foil to reduce resistive losses and improve cross regulation. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 41 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.4 ep13 115 v ac transformer drawing set-top gx erl28 transformer 10 14 13 wdg #4 4t 2x 27 awg wdg #3b 1t cu foil wdg #3a 2t cu foil 11 12 9 primary 4 wdg#2 7t 2 x 27 awg wdg#7 23t 25awg 1 3 7 6 wdg #1 30t 25awg bias 3.3 v 5 v 12 v wdg #5 3t 2 x 27awg 18 v wdg #6 6t 8 shield 15.5 electrical specifications electrical strength 60 hz 1 minute, from pins 1-7 to pins 8-14 3000 vac primary inductance pins 1-4, all other windings open, 100 khz 356 h resonant frequency pins 1-4, all other windings open 1.1 mhz primary leakage inductance pins 1-4, pins 8-12 shorted, 100 khz <11 h EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 42 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.6 materials item description [1] core: erl28, nippon ceramic nc-2h material or equivalent gap for a l of 128 nh/t 2 [2] bobbin: erl28 vertical, 14 pins, jinbo industrial jb-0039 or equivalent [3] magnet wire: #25 awg solderable double coated [4] magnet wire: #27 awg solderable double coated [5] copper foil 0.60? x .005? [6] copper foil 0.60? x .001? [7] tinned bus wire, 22 awg [8] tape: 3m type 1298 polyester film or equiv. 22.4 mm wide [9] tape: 3m type 1298 polyester film or equiv. 16 mm wide [10] tape: 3m type 44. polyester web or equiv. 3.2 mm wide (min) [11] transformer varnish 15.7 transformer construction diagram 1 t a ? primary secondaries bias 13 6 3 4 3 7 1 14 12 ? primary 12 13 8 9 11 10 shield bobbin pin side tape 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 43 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.8 winding instructions bobbin preparation remove pins 2 and 5 on bobbin. margin taping apply a 3.2 mm margin at each side of bobbin using item [10]. match combined height of 1 st primary, shield and bias windings. 1 st primary winding start at pin 4. wind 30 turns of item [3] uniformly across the bobbin in one layer. finish at pin 3. basic insulation apply one layer of tape [9] for basic insulation. shield prepare shield assembly using items [4] and [6]. position shield assembly so that termination wire is adjacent to pin 1. wrap foil around bobbin, and insulate between overlapping foil ends using tape [9]. terminate drain wire at pin 1. basic insulation apply one layer of tape [9] for basic insulation. bifilar bias winding start at pin 6. wind 7 bifilar turns of item [4] uniformly in a single layer, across entire width of bobbin. finish on pin 7. reinforced insulation apply three layers of tape [8] for reinforced insulation. margin taping apply a 3.2 mm margin at each side of bobbin using item [10]. match combined height of secondary windings. copper foil winding prepare cuffed foil assembly as shown below, using items [5], [7], [8], and [9]. start foil winding at pin 9. wind 1 turn and terminate tap at pin 11. wind 2 additional turns and finish at pin 10. basic insulation apply one layer of tape [9] for basic insulation. +12 v bifilar winding starting at pin12, wind 4 bifilar turns of item [4] evenly across bobbin. finish at pin 8. +18 v bifilar winding starting at pin 13, wind 3 bifilar turns of item [4] directly over the 12 v winding. apply turns evenly across bobbin. finish at pin 12. +30v winding starting at pin 14, wind 6 turns of item [4] directly over the 18 v winding. apply turns evenly across bobbin. finish at pin 13. reinforced insulation apply three layers of tape [8] for reinforced insulation. margin taping apply a 3.2 mm margin at each side of bobbin using item [10]. match height of 2nd primary winding. 2 nd primary winding start at pin 3. wind 23 turns of item [3] uniformly across the bobbin in one layer. finish at pin 1. outer insulation apply 3 layers of tape [8] for outer insulation varnish impregnate transformer using item [11] EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 44 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.8.1 shield foil assembly 2? 2.25? termination wire copper foil [6] 1.1? item [4] shield assembly 15.8.2 secondary foil assembly 2? (3 places) item [7] (3 places) tape [8] copper foil [5] star t tap finish 2.125? secondary foil assembly 15.8.3 design notes power integrations device top247 frequency of operation 132 khz mode continuous peak current 1.71 amps reflected voltage (secondary to primary) 100 v maximum dc input voltage 187 vdc minimum dc input voltage 93 vdc tape [9] (2 places) 6.1? 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 45 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.9 ep13 115 v ac transformer spreadsheets 15.9.1 115 v ac , 60 w peak load acdc_topgx_rev1.1_040401 copyright power integrations inc. 2000 input info output unit top_gx_040401.xls: topswitch-gx continuous/discontinuous flyback transformer design spreadsheet enter application variables customer vacmin 85 volts minimum ac input voltage vacmax 132 volts maximum ac input voltage fl 50 hertz ac mains frequency vo 3.3 volts output voltage po 60 watts output power n 0.7 efficiency estimate z 0.5 loss allocation factor vb 12 volts bias voltage tc 3 mseconds bridge rectifier conduction time estimate cin 150 farads input filter capacitor enter topswitch-gx variables top-gx top247 universal 115 doubled/230 v chosen device top247 power out 105 w 200 w ki 0.8 external ilimit reduction factor (ki=1.0 for default ilimit, ki <1.0 for lower ilimit) ilimitmin 2.592 amps use 1% resistor in setting external ilimit ilimitmax 3.168 amps use 1% resistor in setting external ilimit frequency - (f)=130 khz, (h)=65 khz f full (f) frequency option - 130 khz fs 130000 1.30e+05 hertz topswitch-gx switching frequency: choose between 130 khz and 65 khz fsmin 1.24e+05 hertz topswitch-gx minimum switching frequency fsmax 1.40e+05 hertz topswitch-gx maximum switching frequency vor 100 volts reflected output voltage vds 10 volts topswitch on-state drain to source voltage vd 0.5 volts output winding diode forward voltage drop vdb 0.7 volts bias winding diode forward voltage drop kp 0.40 ripple to peak current ratio (0.4 < krp < 1.0 : 1.0< kdp<6.0) enter transformer core/construction variables core type eer28l core eer28l p/n: pc40eer28l-z bobbin eer28l_bobbin p/n: beer-28l-1112cph ae 0.814 cm^2 core effective cross sectional area le 7.55 cm core effective path length al 2520 nh/t^2 ungapped core effective inductance bw 21.8 mm bobbin physical winding width m3.2mm safety margin width (half the primary to secondary creepage distance) l 2 number of primary layers ns 2 number of secondary turns dc input voltage parameters EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 46 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com vmin 80 volts minimum dc input voltage vmax 187 volts maximum dc input voltage current waveform shape parameters dmax 0.59 maximum duty cycle iavg 1.07 amps average primary current ip 2.27 amps peak primary current ir 0.91 amps primary ripple current irms 1.41 amps primary rms current transformer primary design parameters lp 356 henries primary inductance np 53 primary winding number of turns nb 7 bias winding number of turns alg 128 nh/t^2 gapped core effective inductance bm 1886 gauss maximum flux density at po, vmin (bm<3000) bp 2630 gauss peak flux density (bp<4200) bac 377 gauss ac flux density for core loss curves (0.5 x peak to peak) ur 1860 relative permeability of ungapped core lg 0.76 mm gap length (lg > 0.1 mm) bwe 30.8 mm effective bobbin width od 0.59 mm maximum primary wire diameter including insulation ins 0.07 mm estimated total insulation thickness (= 2 * film thickness) dia 0.52 mm bare conductor diameter awg 24 awg primary wire gauge (rounded to next smaller standard awg value) cm 406 cmils bare conductor effective area in circular mils cma 289 cmils/amp primary winding current capacity (200 < cma < 500) transformer secondary design parameters (single output / single output equivalent) lumped parameters isp 59.79 amps peak secondary current isrms 31.05 amps secondary rms current io 18.18 amps power supply output current iripple 25.17 amps output capacitor rms ripple current cms 6211 cmils secondary bare conductor minimum circular mils awgs 12 awg secondary wire gauge (rounded up to next larger standard awg value) dias 2.05 mm secondary minimum bare conductor diameter ods 7.70 mm secondary maximum outside diameter for triple insulated wire inss 2.82 mm maximum secondary insulation wall thickness voltage stress parameters vdrain 417 volts maximum drain voltage estimate (includes effect of leakage inductance) pivs 10 volts output rectifier maximum peak inverse voltage pivb 36 volts bias rectifier maximum peak inverse voltage transformer secondary design parameters (multiple outputs) 1st output vo1 5.0 volts output voltage io1 3.200 amps output dc current po1 16.00 watts output power vd1 0.7 volts output diode forward voltage drop 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 47 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com ns1 3.00 output winding number of turns isrms1 5.465 amps output winding rms current iripple1 4.43 amps output capacitor rms ripple current pivs1 16 volts output rectifier maximum peak inverse voltage cms1 1093 cmils output winding bare conductor minimum circular mils awgs1 19 awg wire gauge (rounded up to next larger standard awg value) dias1 0.91 mm minimum bare conductor diameter ods1 5.13 mm maximum outside diameter for triple insulated wire 2nd output vo2 12.0 volts output voltage io2 0.600 amps output dc current po2 7.20 watts output power vd2 1.4 volts output diode forward voltage drop ns2 7.05 output winding number of turns isrms2 1.025 amps output winding rms current iripple2 0.83 amps output capacitor rms ripple current pivs2 37 volts output rectifier maximum peak inverse voltage cms2 205 cmils output winding bare conductor minimum circular mils awgs2 26 awg wire gauge (rounded up to next larger standard awg value) dias2 0.41 mm minimum bare conductor diameter ods2 2.18 mm maximum outside diameter for triple insulated wire 3rd output vo3 18.0 volts output voltage io3 0.500 amps output dc current po3 9.00 watts output power vd3 1.4 volts output diode forward voltage drop ns3 10.21 output winding number of turns isrms3 0.854 amps output winding rms current iripple3 0.69 amps output capacitor rms ripple current pivs3 54 volts output rectifier maximum peak inverse voltage cms3 171 cmils output winding bare conductor minimum circular mils awgs3 27 awg wire gauge (rounded up to next larger standard awg value) dias3 0.36 mm minimum bare conductor diameter ods3 1.51 mm maximum outside diameter for triple insulated wire EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 48 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.9.2 115 v ac , 45 w steady state load acdc_topgx_rev1.1_04040 1 copyright power integrations inc. 2000 input info output unit top_gx_040401.xls: topswitch-gx continuous/discontinuous flyback transformer design spreadsheet enter application variables customer vacmin 85 volts minimum ac input voltage vacmax 132 volts maximum ac input voltage fl 50 hertz ac mains frequency vo 3.3 volts output voltage po 45 watts output power n 0.7 efficiency estimate z 0.5 loss allocation factor vb 12 volts bias voltage tc 3 mseconds bridge rectifier conduction time estimate cin 150 farads input filter capacitor enter topswitch-gx variables top-gx top247 universal 115 doubled/230 v chosen device top247 power out 105 w 200 w ki 0.8 external ilimit reduction factor (ki=1.0 for default ilimit, ki <1.0 for lower ilimit) ilimitmin 2.592 amps use 1% resistor in setting external ilimit ilimitmax 3.168 amps use 1% resistor in setting external ilimit frequency - (f)=130 khz, (h)=65 khz f full (f) frequency option - 130 khz fs 130000 1.30e+05 hertz topswitch-gx switching frequency: choose between 130 khz and 65 khz fsmin 1.24e+05 hertz topswitch-gx minimum switching frequency fsmax 1.40e+05 hertz topswitch-gx maximum switching frequency vor 100 volts reflected output voltage vds 10 volts topswitch on-state drain to source voltage vd 0.5 volts output winding diode forward voltage drop vdb 0.7 volts bias winding diode forward voltage drop kp 0.55 ripple to peak current ratio (0.4 < krp < 1.0 : 1.0< kdp<6.0) enter transformer core/construction variables core type eer28l core eer28l p/n: pc40eer28l-z bobbin eer28l_bobbin p/n: beer-28l-1112cph ae 0.814 cm^2 core effective cross sectional area le 7.55 cm core effective path length al 2520 nh/t^2 ungapped core effective inductance bw 21.8 mm bobbin physical winding width m3.2mm safety margin width (half the primary to secondary creepage distance) l 2 number of primary layers ns 2 number of secondary turns dc input voltage parameters vmin 92 volts minimum dc input voltage vmax 187 volts maximum dc input voltage current waveform shape parameters 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 49 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com dmax 0.55 maximum duty cycle iavg 0.70 amps average primary current ip 1.75 amps peak primary current ir 0.97 amps primary ripple current irms 0.97 amps primary rms current transformer primary design parameters lp 359 henries primary inductance np 53 primary winding number of turns nb 7 bias winding number of turns alg 130 nh/t^2 gapped core effective inductance bm 1470 gauss maximum flux density at po, vmin (bm<3000) bp 2654 gauss peak flux density (bp<4200) bac 404 gauss ac flux density for core loss curves (0.5 x peak to peak) ur 1860 relative permeability of ungapped core lg 0.75 mm gap length (lg > 0.1 mm) bwe 30.8 mm effective bobbin width od 0.59 mm maximum primary wire diameter including insulation ins 0.07 mm estimated total insulation thickness (= 2 * film thickness) dia 0.52 mm bare conductor diameter awg 24 awg primary wire gauge (rounded to next smaller standard awg value) cm 406 cmils bare conductor effective area in circular mils cma 421 cmils/amp primary winding current capacity (200 < cma < 500) transformer secondary design parameters (single output / single output equivalent) lumped parameters isp 46.18 amps peak secondary current isrms 23.00 amps secondary rms current io 13.64 amps power supply output current iripple 18.52 amps output capacitor rms ripple current cms 4600 cmils secondary bare conductor minimum circular mils awgs 13 awg secondary wire gauge (rounded up to next larger standard awg value) dias 1.83 mm secondary minimum bare conductor diameter ods 7.70 mm secondary maximum outside diameter for triple insulated wire inss 2.94 mm maximum secondary insulation wall thickness voltage stress parameters vdrain 417 volts maximum drain voltage estimate (includes effect of leakage inductance) pivs 10 volts output rectifier maximum peak inverse voltage pivb 36 volts bias rectifier maximum peak inverse voltage transformer secondary design parameters (multiple outputs) 1st output vo1 5.0 volts output voltage io1 3.200 amps output dc current po1 16.00 watts output power vd1 0.7 volts output diode forward voltage drop ns1 3.00 output winding number of turns isrms1 5.397 amps output winding rms current EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 50 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com iripple1 4.35 amps output capacitor rms ripple current pivs1 16 volts output rectifier maximum peak inverse voltage cms1 1079 cmils output winding bare conductor minimum circular mils awgs1 19 awg wire gauge (rounded up to next larger standard awg value) dias1 0.91 mm minimum bare conductor diameter ods1 5.13 mm maximum outside diameter for triple insulated wire 2nd output vo2 12.0 volts output voltage io2 0.600 amps output dc current po2 7.20 watts output power vd2 1.4 volts output diode forward voltage drop ns2 7.05 output winding number of turns isrms2 1.012 amps output winding rms current iripple2 0.81 amps output capacitor rms ripple current pivs2 37 volts output rectifier maximum peak inverse voltage cms2 202 cmils output winding bare conductor minimum circular mils awgs2 27 awg wire gauge (rounded up to next larger standard awg value) dias2 0.36 mm minimum bare conductor diameter ods2 2.18 mm maximum outside diameter for triple insulated wire 3rd output vo3 30.0 volts output voltage io3 0.030 amps output dc current po3 0.90 watts output power vd3 1.4 volts output diode forward voltage drop ns3 16.53 output winding number of turns isrms3 0.051 amps output winding rms current iripple3 0.04 amps output capacitor rms ripple current pivs3 89 volts output rectifier maximum peak inverse voltage cms3 10 cmils output winding bare conductor minimum circular mils awgs3 39 awg wire gauge (rounded up to next larger standard awg value) dias3 0.09 mm minimum bare conductor diameter ods3 0.93 mm maximum outside diameter for triple insulated wire 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 51 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 15.10 list of included parts for 230 vac-115 vac conversion set-top gx, 115 v, conversion kit bill of materials item qty reference description p/n manufacturer 1 1 c2 150 f, 200 veb eeu-eb2d151 panasonic 2 4 c13,14,16,17 1200 f, 35 v fa eeu-fa1v122l panasonic 3 2 c21,22 0.1 f, 50 v k104m15z5uf5th5 beyerschlag/centralab 4 4 d1-4 2 a, 600 v rl205 diodes, inc. 5 1 l1 18 mh, 1.3 a elf-20n013a panasonic 6 1 r12 18 k ? , 1/4 w, 5% 7 1 t1 transformer, custom, erl28 81u1 top247y 9 1 rt1 thermistor, 10 ? , 3.2 a kc011l keystone 10 1 jp5 zero ohm resistor 15.11 ep13 230 vac-115 vac conversion instructions 15.11.1 required tools and supplies 1) soldering iron 2) solder 3) pliers 4) desoldering tool/solder wick 5) philips screwdriver 6) thermal compound 15.11.2 conversion instructions 1) remove c2, c13-17, d1-4, l1, t1, u1, and rt1. retain mounting screw and nut from u1 heat sink for reuse. 2) replace c2 with 150 f, 200 v capacitor from conversion kit. observe proper polarity. 3) replace c13, 14, 16, and 17 with 1200 f, 35 v capacitors from conversion kit. observe proper polarity. 4) replace d1-4 with rl205 diodes from conversion kit. check for proper diode polarity according to pcb silkscreen. 5) replace l1 with 18 mh common mode inductor from conversion kit. 6) replace u1 with top247y from conversion kit. use thermal compound between device mounting tab and heat sink to assure proper thermal interface. 7) replace t1 with transformer from conversion kit. 8) replace rt1 with thermistor from conversion kit. 9) populate c21 and c22 positions with 0.1 f capacitors from conversion kit. 10) populate r12 position with 18 k ? resistor from conversion kit. 11) populate jp5 position using zero ohm resistor from conversion kit. EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 52 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 16 appendix b miscellaneous custom parts 16.1 secondary heat sink figure 41 - ep13 secondary heat sink drawing. 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 53 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 17 revision history date author revision description & changes 25-jan-2001 rh 0.1 first draft 12-apr-2001 rh 0.2 second draft 16-apr-2001 rh 0.3 third draft 08-may-2001 rh 1.0 first release EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 54 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com notes 08-may-2001 EPR-000013 ? 43 w multiple output top246 power supply page 55 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com notes EPR-000013 ? 43 w multiple output top246 power supply 08-may-2001 page 56 of 56 power integrations, inc. tel: +1 408 414 9200 fax: +1 408 414 9201 www.powerint.com 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, nor does it convey any license under its patent rights or the rights of others. pi logo, topswitch and tinyswitch are registered trademarks of power integrations, inc. ?copyright 2001, power integrations, inc. world headquarters north america - west power integrations, inc. 5245 hellyer avenue san jose, ca 95138 usa. main: +14084149200 customer service: phone: +14084149665 fax: +14084149765 north america - east & south america power integrations, inc. eastern area sales office 1343 canton road, suite c1 marietta, ga 30066 usa phone: +17704245152 fax: +17704246567 europe & africa power integrations (europe) ltd. centennial court easthampstead road bracknell berkshire rg12 1yq, united kingdom phone: +441344462301 fax: +441344311732 taiwan power integrations international holdings, inc. 2f, #508, chung hsiao e. rd., sec. 5, taipei 105, taiwan phone: +886227271221 fax: +886227271223 china power integrations international holdings, inc. rm# 1705, bao hua bldg. 1016 hua qiang bei lu shenzhen guangdong, 518031 phone: +867553675143 fax: +867553779610 korea power integrations international holdings, inc. rm# 402, handuk building, 649-4 yeoksam-dong, kangnam-gu, seoul, korea phone: +8225687520 fax: +8225687474 japan power integrations, k.k. keihin-tatemono 1st bldg. 12-20 shin-yokohama 2- chome, kohoku-ku, yokohama-shi, kanagawa 222, japan phone: +81454711021 fax: +81454713717 india (technical support) innovatech #1, 8th main road vasanthnagar bangalore, india 560052 phone: +91802266023 fax: +91802289727 applications hotline world wide +14084149660 applications fax world wide +14084149760 |
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