RDK-142

RDK-142

  • 厂商:

    POWERINT(帕沃英蒂格盛)

  • 封装:

    -

  • 描述:

    TOP258 TOPSwitch®-HX AC/DC, Primary Side 2, Non-Isolated Outputs Evaluation Board

  • 数据手册
  • 价格&库存
RDK-142 数据手册
Title Reference Design Report for a 35 W Power Supply Using TOPSwitchTM-HX TOP258PN Specification 90 VAC to 265 VAC Input; 5 V, 2.2 A and 12 V, 2 A Outputs Application LCD Monitor Author Applications Engineering Department Document Number RDR-142 Date August 07, 2014 Revision 1.3 Summary and Features • Low cost, low component count, high efficiency • Delivers 35 W at 50 °C ambient without requiring an external heat sink • Meets output cross regulation requirements without linear regulators • EcoSmartTM – meets requirements for low no-load and standby power consumption • 0.42 W output power for 82% full load efficiency • Integrated safety/reliability features • Accurate, auto-recovering, hysteretic thermal shutdown function maintains safe PCB temperatures under all conditions • Auto-restart protects against output short-circuits and open feedback loops • Output OVP protection configurable for latching or self-recovering • Input UV prevents power up / power down output glitches • Meets EN55022 and CISPR-22 Class B conducted EMI with >10 dBµV margin The products and applications illustrated herein (including circuits external to the products and transformer construction) 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 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Aug-14 Table of Contents 1 2 3 4 Introduction ................................................................................................................. 4 Power Supply Specification ........................................................................................ 5 Schematic ................................................................................................................... 6 Circuit Description ...................................................................................................... 7 4.1 Input EMI Filtering ............................................................................................... 7 4.2 TOPSwitch-HX Primary ....................................................................................... 7 4.3 Output Rectification ............................................................................................. 8 4.4 Output Feedback ................................................................................................. 9 4.5 PCB Layout ....................................................................................................... 10 5 Bill of Materials ......................................................................................................... 11 6 Transformer Specification ......................................................................................... 13 6.1 Electrical Diagram ............................................................................................. 13 6.2 Electrical Specifications ..................................................................................... 13 6.3 Materials ............................................................................................................ 13 6.4 Transformer Build Diagram ............................................................................... 14 6.5 Transformer Construction .................................................................................. 15 7 Transformer Design Spreadsheet............................................................................. 16 8 Performance Data .................................................................................................... 20 8.1 Efficiency ........................................................................................................... 20 8.1.1 Active Mode CEC Measurement Data........................................................ 21 8.2 No-Load Input Power ........................................................................................ 22 8.3 Available Standby Output Power ....................................................................... 23 9 Regulation ................................................................................................................ 24 9.1.1 Load ........................................................................................................... 24 9.1.2 Line ............................................................................................................ 25 9.1.3 Cross Regulation Matrix ............................................................................. 26 10 Thermal Performance ........................................................................................... 27 11 Waveforms ............................................................................................................ 29 11.1 Drain Voltage and Current, Normal Operation................................................... 29 11.2 Output Voltage Start-up Profile.......................................................................... 29 11.3 Drain Voltage and Current Start-up Profile ........................................................ 31 11.4 Load Transient Response (75% to 100% Load Step) ....................................... 32 11.5 Output Overvoltage Protection .......................................................................... 34 11.6 Output Ripple Measurements ............................................................................ 35 11.6.1 Ripple Measurement Technique ................................................................ 35 11.6.2 Measurement Results ................................................................................ 36 12 Line Surge............................................................................................................. 38 13 Control Loop Measurements ................................................................................. 39 13.1 90 VAC Maximum Load..................................................................................... 39 13.2 265 VAC Maximum Load................................................................................... 40 14 Conducted EMI ..................................................................................................... 41 15 Revision History .................................................................................................... 42 Important Note: Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 43 07-Aug-14 RDR-142 35 W, TOP258PN Dual Output Supply 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 isolation transformer to provide the AC input to the prototype board. Page 3 of 43 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Aug-14 1 Introduction This document is an engineering report describing a LCD Monitor power supply utilizing a TOP258PN. This power supply is intended as a general purpose evaluation platform for TOPSwitch-HX. 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 (5”L x 2.84”W x 1.16”H). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 43 07-Aug-14 RDR-142 35 W, TOP258PN Dual Output Supply 2 Power Supply Specification Description Symbol Min Typ Max Units Comment 265 64 0.3 VAC Hz W 3 Wire Input 5.25 100 2.2 14.4 V mV A V ± 5% 20 MHz Bandwidth 500 mV 20 MHz Bandwidth 2 A Input Voltage Frequency No-load Input Power (230 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 VIN fLINE 90 47 50/60 VOUT1 VRIPPLE1 IOUT1 VOUT2 4.75 5 0 9.6 12 Output Ripple Voltage 2 VRIPPLE2 Output Current 2 Total Output Power Continuous Output Power Efficiency Full Load IOUT2 0 POUT η 35 Required Average Efficiency at 25, 50, 75 and 100 % of POUT W 82 Standby Input Power * W Measured at POUT 25 oC 5 V @ 82 mA, 12 V @ 0 mA; VIN at 264 VAC % Per California Energy Commission (CEC) / Energy Star requirements % 1 ηCEC ± 20% 81 Environmental Conducted EMI Meets CISPR22B / EN55022B Designed to meet IEC950, UL1950 Class II Safety Surge Differential Common Mode Surge Ring Wave Ambient Temperature TAMB 1 2 kV kV 1 kV 0 50 o C 1.2/50 µs surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ω Common Mode: 12 Ω 100 kHz ring wave, 500 A Short Circuit Current, Differential and Common Mode Free Convection, Sea Level *Shown for information only as CEC requirement does not apply to internal power supplies Page 5 of 43 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Aug-14 3 Schematic * *Optional for 2-wire input, floating output Figure 2 – Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 43 07-Aug-14 RDR-142 35 W, TOP258PN Dual Output Supply 4 Circuit Description A flyback converter configuration built around TOP258PN is used in this power supply to obtain two output voltages. The 5 V output can supply a load current of 2.2 A, and the 12 V output can supply a load current of 2.0 A. This power supply can operate between 90 – 264 VAC. The 5 V output is the main regulated output. This output is regulated using a TL431 voltage reference. Some feedback is also derived from the 12 V output for improved cross regulation. 4.1 Input EMI Filtering The three wire AC supply is connected to the circuit using connector J1. Fuse F1 provides protection against circuit faults and effectively isolates the circuit from the AC supply source. Thermistor RT1 limits the inrush current drawn by the circuit at start up. Optional capacitors C1 and C2 are Y capacitors connected from the Line/Neutral to Earth to reduce common mode EMI. Capacitor C3 is the X capacitor and helps to reduce the differential mode EMI. Resistors R1 and R2 discharge C3 on AC removal, preventing potential user shock. Inductor L1 is a common-mode inductor and helps in filtering common-mode EMI from coupling back to the AC source. Diodes D1, D2, D3 and D4 form a bridge rectifier. The bridge rectifier rectifies the incoming AC supply to DC, which is filtered by capacitor C4. Diodes D1 and D3 are fast recovery type diodes. These diodes recover very quickly when the voltage across them reverses. This reduces excitation of stray line inductance in the AC input by reducing the subsequent high frequency turnoff snap and hence EMI. Only 2 of the 4 diodes in the bridge need to be fast recovery type, since 2 diodes conduct in each half cycle. 4.2 TOPSwitch-HX Primary Resistor R3 and R4 provide line voltage sensing and provide a current to U1, which is proportional to the DC voltage across capacitor C4. At approximately 95 V DC, the current through these resistors exceeds the line under-voltage threshold of 25 µA, which results in enabling of U1. The TOPSwitch-HX IC regulates the output using PWM-based voltage mode control. At high loads the controller operates at full switching frequency (66 kHz for P package devices). The duty cycle is controlled based on the CONTROL pin current to regulate the output voltage. The internal current limit provides cycle-by-cycle peak current limit protection. The TOPSwitch-HX controller has a second current limit comparator allowing monitoring the actual peak drain current (IP) relative to the programmed current limit ILIMITEXT. As soon as the ratio IP/ILIMITEXT falls below 55%, the peak drain current is held constant. The output is Page 7 of 43 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Aug-14 then regulated by modulating the switching frequency (variable frequency PWM control). As the load decreases further, the switching frequency decreases linearly from full frequency down to 30 kHz. Once the switching frequency has reached 30 kHz the controller keeps this switching frequency constant and the peak current is reduced to regulate the output (fixed frequency, direct duty cycle PWM control). As the load is further reduced and the ratio IP/ILIMITEXT falls below 25%, the controller will enter a multi-cycle-modulation mode for excellent efficiency at light load or standby operation and low no-load input power consumption. Diode D5, together with R6, R7, C6 and Zener VR1, forms a clamp network that limits the drain voltage of U1 at the instant of turn-off. Zener VR1 provides a defined maximum clamp voltage and typically only conducts during fault conditions such as overload. This allows the RCD clamp (R6, C6 and D5) to be sized for normal operation, thereby maximizing efficiency at light load. Resistor R7 is required due to the choice of a fast recovery diode for D5. A fast versus ultrafast recovery diode allows some recovery of the clamp energy but requires R7 to limit reverse diode current and dampen high frequency ringing. The output of the bias winding is rectified by diode D6 and filtered by resistor R10 and capacitor C10. This rectified and filtered output is used by the optocoupler U2 to provide the control current to the control terminal of U1. Should the feedback circuit fail (open loop condition), the output of the power supply will exceed the regulation limits. This increased voltage at output will also result in an increased voltage at the output of the bias winding. Zener VR2 will break down and current will flow into the “M” pin of IC U1, thus initiating a hysteretic OVP shutdown with automatic restart attempts. Resistor R5 limits the current into the M pin; if latching OVP is desired, the value of R5 can be reduced to 20 Ω. The output voltage of the power supply is maintained in regulation by the feedback circuit on the secondary side of the circuit. The feedback circuit controls the output voltage by changing the optocoupler current. Change in the optocoupler diode current results in a change of current into the control pin of IC U1. Variation of this current results in variation of duty cycle and hence the output voltage of the power supply. 4.3 Output Rectification Output rectification for the 5 V output is provided by diode D8. Low ESR capacitor C17 provides filtering. Inductor L3 and capacitor C18 form a second stage filter that significantly attenuates the switching ripple across C17 and ensures a low ripple output. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 43 07-Aug-14 RDR-142 35 W, TOP258PN Dual Output Supply Output rectification for the 12 V output is provided by diode D7. Low ESR capacitors C13 and C14 provide filtering. Inductor L2 and capacitor C15 form a second stage filter that significantly attenuates the switching ripple and ensures low ripple at the output. Snubber networks comprising R11, C12 and R12, and C16 damp high frequency ringing across diodes D7 and D8, which results from leakage inductance of the transformer windings and the secondary trace inductances. 4.4 Output Feedback Output voltage is controlled using the shunt regulator TL431 (U3). Diode D9, capacitor C20 and resistor R16 form the soft finish circuit. At start-up, capacitor C20 is discharged. As the output voltage starts rising, current flows into the optocoupler diode (U2A) via resistor R13 and diode D9. This provides feedback to the circuit on the primary side. The current in the optocoupler diode U2A gradually decreases as capacitor C20 charges and U3 becomes operational. This ensures that the output voltage increases gradually and settles to the final value without any overshoot. Resistor R16 provides a discharge path for C20 into the load at power down. Diode D9 isolates C20 from the feedback circuit after start-up. Resistor R18, R20 and R21 form a voltage divider network that senses the output voltage from both the outputs for better cross-regulation. Resistor R19 and Zener VR3 improve cross regulation when only the 5 V output is loaded, which results in the 12 V output operating at the higher end of the specification. Resistors R13, R17 and capacitor C21 set the frequency response of the feedback circuit. Capacitor C19 and resistor R14 form the phase boost network that provides adequate phase margin to ensure stable operation over the entire operating voltage range. Resistor R15 provides the bias current required by the IC U3 and is placed in parallel with U2A to ensure that the bias current to the IC does not become a part of the feedback current. Resistor R13 sets the overall DC loop gain and limits the current through U2A during transient conditions. Page 9 of 43 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 4.5 07-Aug-14 PCB Layout Figure 3 – Printed Circuit Layout. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 43 07-Aug-14 RDR-142 35 W, TOP258PN Dual Output Supply 5 Bill of Materials Item 2 Qty 1 Ref Des C3 3 1 C4 4 5 6 7 8 9 1 2 1 1 2 2 C6 C7 C11 C8 C9 C10 C20 C12 C16 10 2 C13 C14 11 1 C15 12 1 C17 13 1 C18 14 15 1 1 C19 C21 16 2 D1 D3 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 2 2 1 1 1 1 1 2 1 1 1 1 2 2 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 D2 D4 D5 D6 D7 D8 D9 F1 J1 J2 J3 JP1 JP2 JP3 L1 L2 L3 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 RT1 48 1 T1 Page 11 of 43 Description 220 nF, 275 VAC, Film, X2 100 µF, 400 V, Electrolytic, Low ESR, 630 mΩ (16 x 40) 3.9 nF, 1 kV, Disc Ceramic, Y5P 2.2 nF, Ceramic, Y1 100 nF, 50 V, Ceramic, Z5U 47 µF, 16 V, Electrolytic, Gen Purpose, (5 x 11.5) 10 µF, 50 V, Electrolytic, Gen Purpose, (5 x 11) 470 pF, 100 V, Ceramic, COG 680 µF, 25 V, Electrolytic, Very Low ESR, 23 mΩ, (10 x 20) 220 µF, 25 V, Electrolytic, Low ESR, 120 mΩ, (8 x 12) 2200 µF, 10 V, Electrolytic, Very Low ESR, 21 mΩ, (12.5 x 20) 220 µF, 10 V, Electrolytic, Low ESR, 250 mΩ, (6.3 x 11.5) 1.0 µF, 50 V, Ceramic, X7R 220 nF, 50 V, Ceramic, X7R 600 V, 1 A, Fast Recovery Diode, 200 ns, DO-41 1000 V, 1 A, Rectifier, DO-41 800 V, 1 A, Fast Recovery Diode, 500 ns, DO-41 60 V, 5 A, Schottky, DO-201AD 30 V, 5 A, Schottky, DO-201AD 75 V, 300 mA, Fast Switching, DO-35 3.15 A, 250V,Fast, TR5 5 Position (1 x 5) header, 0.156 pitch 2 Position (1 x 2) header, 0.156 pitch Wire Jumper, Non insulated, #22 AWG, 0.4 in Wire Jumper, Non insulated, #22 AWG, 0.8 in Wire Jumper, Non insulated, #22 AWG, 0.3 in 6.8 mH, 0.8 A, Common Mode Choke 3.3 µH, 5.0 A 1 MΩ, 5%, 1/4 W, Carbon Film 2.0 MΩ, 5%, 1/4 W, Carbon Film 5.1 kΩ, 5%, 1/4 W, Carbon Film 22 kΩ, 5%, 2 W, Metal Oxide 20 Ω, 5%, 1/2 W, Carbon Film 6.8 Ω, 5%, 1/8 W, Carbon Film 100 Ω, 5%, 1/4 W, Carbon Film 0 Ω, 5%, 1/4 W, Carbon Film 33 Ω, 5%, 1/4 W, Carbon Film 330 Ω, 5%, 1/4 W, Carbon Film 22 Ω, 5%, 1/4 W, Carbon Film 1 kΩ, 5%, 1/4 W, Carbon Film 10 kΩ, 5%, 1/4 W, Carbon Film 196 kΩ, 1%, 1/4 W, Metal Film 10 Ω, 5%, 1/4 W, Carbon Film 12.4 kΩ, 1%, 1/4 W, Metal Film 10 kΩ, 1%, 1/4 W, Metal Film NTC Thermistor, 10 Ω, 1.7 A Core Bobbin: EER28, Horizontal, 12 pins (6/6), Mfg Part Number ECQ-U2A224ML B37984M5105K000 B37987F5224K000 Mfg Panasonic Nippon Chemi-Con Panasonic Vishay Kemet Panasonic Panasonic AVX Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Nippon Chemi-Con Epcos Epcos 1N4937RLG On Semi 1N4007 FR106 SB560 SB530 1N4148 37013150410 26-48-1055 26-48-1025 298 298 298 ELF15N008 RFB0807-3R3L CFR-25JB-1M0 CFR-25JB-2M0 CFR-25JB-5K1 RSF200JB-22K CFR-50JB-20R CFR-12JB-6R8 CFR-25JB-100R ZOR-25-B-52-0R CFR-25JB-33R CFR-25JB-330R CFR-25JB-22R CFR-25JB-1K0 CFR-25JB-10K MFR-25FBF-196K CFR-25JB-10R MFR-25FBF-12K4 ERO-S2PHF1002 CL-120 PC40EER28-Z YC-2806-5 Vishay Diodes, Inc. Vishay Fairchild Vishay Wickman Molex Molex Alpha Alpha Alpha Panasonic Coilcraft Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Panasonic Thermometrics TDK Ying-Chin EKMX401ELL101ML40S ECK-A3A392KBP 440LD22-R C317C104M5U5TA ECA-1CHG470 ECA-1HHG100 5NK471KOBAM EKZE250ELL681MJ20S ELXZ250ELL221MH12D EKZE100ELL222MK20S ELXZ100ELL221MFB5D Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply Complete Assembly (custom) 49 50 51 52 53 54 1 1 1 1 1 1 U1 U2 U3 VR1 VR2 VR3 TOPSwitch-HX, DIP-8B Optocoupler, 80 V, CTR 80-160%, 4-DIP 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92 200 V, 600 W, 5%, TVS, DO204AC (DO-15) 20 V, 5%, 500 mW, DO-35 8.2 V, 500 mW, 2%, DO-35 07-Aug-14 TP07074 32/07 TR.RDK-142 019-4967-00R SNX R1359 TOP258PN PS2501-1-H-A TL431CLPG P6KE200ARLG 1N5250B BZX55B8V2 Ice Components Magtel Precision Inc. Santronics Power Integrations NEC On Semi On Semi Microsemi Vishay Note – Parts listed above are RoHS compliant Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 43 07-Aug-14 RDR-142 35 W, TOP258PN Dual Output Supply 6 Transformer Specification 6.1 Electrical Diagram Figure 4 – Transformer Electrical Diagram. 6.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 6.3 3000 VAC 1040 µH, ±10% 1000 kHz (Min.) 20 µH (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] 1 second, 60 Hz, from pins 2, 3, 4, 5, 6 to pins 7, 9, 11. Pins 2-4, all other windings open, measured at 100 kHz, 0.4 VRMS. Pins 2-4, all other windings open. Pins 2-4, with Pins 7-9 shorted, measured at 100 kHz, 0.4 VRMS. Description 2 Core: EER28 gapped for ALG of 213 nH/T . Bobbin: EER28, Horizontal 12 pins (6/6), YC-2806-5. Magnet Wire: #27 AWG, double coated. Magnet Wire: #26 AWG, double coated. Tape: 3M Polyester Film, 2.0 mils thick, 16.0 mm wide. Tape: 3M Polyester Film, 2.0 mils thick, 10.0 mm wide. Copper Foil, 2 mils thick, 142 mm long, 8.5 mm wide. To be wrapped over with tape item [6]. Tape: 3M Polyester Film, 2.0 mils thick, 13.5 mm wide. Bare Wire: #28 AWG. Tape: 3M Polyester Film, 2.0 mils thick, 8.0 mm wide. Varnish. Polyester Web Margin Tape 3.1 mm wide. Page 13 of 43 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 6.4 07-Aug-14 Transformer Build Diagram 2 3 11 7 9 11 5 6 3 4 margin tape ( 3.1 mm pre-molded margin bobbin) Bobbin: EER28 (Horizontal, 12pins, 6/6), YC-2806-5) Lp(2-4): 1.04mH +/- 5% Tape: 3M Polyester Film – 2mil thick 2 x #28AWG connected to pin 7 Copper Foil – 2mil thick 2 x #28AWG connected to pin 11 8.5mm 13.5mm 142mm Figure 5 – Transformer Build Diagram. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 43 07-Aug-14 6.5 RDR-142 35 W, TOP258PN Dual Output Supply Transformer Construction General Note WD1 1/2 Primary Insulation WD2 Bias Insulation WD3 st 1 Secondary Insulation nd 2 WD4 Secondary Insulation WD5 2/2 Primary Insulation Assembly Finish Page 15 of 43 Primary side of the bobbin orients to the left hand side. Place 3.1 mm margin tape on both sides for all windings except WD1 due to built-in 3.1 mm margin of bobbin [12]. Winding direction is clockwise. Start on pin 4, wind 24 turns of item [3] from left to right with tight tension and bring the wire across the bobbin to terminate at pin 3. 2 layers of tape item [5]. Start on pin 6, wind 7 turns bifilar of item [4] from left to right, spread the winding evenly, and bring the wire across the bobbin to terminate on pin 5. 2 layers of tape item [5]. Start on pin 11, wind 3 turns of item [7] and terminate at pin 9. 1 layer of tape item [5]. Start on pin 7, wind 4 turns quadfilar of item [4] from right to left, spread the winding evenly across the bobbin, and bring the wire back to the right to terminate on pin 11. 2 layers of tape item [5]. Start on pin 3, wind 23 turns of item [3] from left to right with tight tension, place 1 layer tape item [6], then wind another 23 turns of item [3] from right to left, also with tight tension, and terminate at pin 2. 3 layers of tape item [5]. 2 Grind the cores to get 1038 µH with ALG of 213 nH/T . Secure the cores by wrapping around 2 halves of cores with item [10]. Dip varnish uniformly in item [11]. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-142 35 W, TOP258PN Dual Output Supply 07-Aug-14 7 Transformer Design Spreadsheet ACDC_TOPSwitchHX_09 0607; Rev.1.2; Copyright INPUT Power Integrations 2007 ENTER APPLICATION VARIABLES VACMIN 90 VACMAX 265 fL 50 VO 5.00 PO_AVG 35.00 PO_PEAK n 0.80 Z 0.50 VB 12 tC 3.00 CIN 100.0 ENTER TOPSWITCH-HX VARIABLES TOPSwitch-HX INFO OUTPUT 35.00 Info 100 TOP258PN TOP258 PN Chosen Device KI Power Out UNIT Volts Volts Hertz Volts Watts Watts %/100 Volts mSeconds uFarads Universal / Peak 35 W / 50 W 1.00 ILIMITMIN_EXT ILIMITMAX_EXT Frequency (F)=132kHz, (H)=66kHz 1.534 1.766 H Amps Amps H fS 66000 Hertz fSmin 59400 Hertz fSmax 72600 Hertz High Line Operating Mode VOR TOPSwitch_HX_090607: TOPSwitch-HX Continuous/Discontinuous Flyback Transformer Design Spreadsheet RD-142 Minimum AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Output Voltage (main) Average Output Power Peak Output Power Efficiency Estimate Loss Allocation Factor Ensure proper operation at no load. Bridge Rectifier Conduction Time Estimate Input Filter Capacitor 115 Doubled/230V 48W External Ilimit reduction factor (KI=1.0 for default ILIMIT, KI
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