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TABLE 1: ELECTRICAL SPECIFICATIONS AT 25
O
C
FIGURE 1: SCHEMATIC DIAGRAM
SWITCHING TRANSFORMER DESIGNED FOR USE WITH POWER INTEGRATIONS PWR-TOP227Y. REFER TO APPLICATION CIRCUITS OF FIGURE 3. SPEC LIMITS TYP. 750
WHITE DOT DENOTES PIN #1 (HOT RAIL) 1 PRIMARY (DRAIN) 3 (+BIAS) 5 BIAS (HOT RETURN) 6 SECONDARY PINS #12 & 11, #8 & 7 MUST BE RESPECTIVELY CONNECTED TOGETHER FOR PROPER OPERATION. I.E. CONNECTED AS ONE PARALLEL WINDING. 7,8 (+30V RETURN) 11,12 (+30V)
PARAMETER PRIMARY INDUCTANCE (3-1) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ TURN RATIO'S: SEC (11,12-7,8) : PRIMARY (3-1) BIAS (5-6) : PRIMARY (3-1) PRI LEAKAGE IND. (SEC SHORTED) VOLTAGE = 0.250Vrms FREQUENCY = 100 KHZ HIPOT: 50/60Hz, 1 Minute Minimum PRIMARY TO SECONDARY BIAS TO SECONDARY FIGURE 3 CIRCUIT PARAMETERS: (1) AC LINE VOLTAGE 47/400 Hz OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS OUTPUT CURRENT PEAK LINE REGULATION (85 TO 265Vac) LOAD REGULATION 10-100% RIPPLE
MIN. 675
MAX. 825
UNITS HY
----------------------
1:4.000 1:9.333 8.5
--------------12.0
+ 4% + 4% HY
SECONDARY
3750 3750 85 0.10 -----------------------------
---------------------30.0 --------------0.20 0.20 50.0
--------------265 3.00 3.20 ----------------------
Vrms Vrms Vac Vdc Amps Amps +% +% +mV
(1) REFER TO APPLICATION CIRCUIT OF FIGURE 3A. FOR 28.0V @ 4.0A, VOLTAGE DOUBLER VERSION REFER TO FIGURE 3B.
NOTE1: REINFORCED INSULATION SYSTEM, UL1950, IEC950, CSA-950: A) ALL MATERIALS MEET "UL", "CSA" & "IEC" REQUIREMENTS B) TRIPLE BASIC INSULATED SECONDARY. C) DESIGNED TO MEET >6.2mm CREEPAGE REQUIREMENTS. D) VARNISH FINISHED ASSEMBLY. E) UL1950 & CSA-950 CERTIFIED: FILE #E162344. F) UL CLASS (B) 130 INSULATION SYSTEM PM130-R1, PM130-H1, PM130-H1A (UL FILE #E177139) OR ANY UL AUTHORIZED CLASS (B) INSULATION SYSTEM.
FIGURE 2: PHYSICAL DIMENSIONS mm (INCHES)
12 11 10 9 8 7
P POL-30030 M YYWW
PIN #1 WHITE DOT 1 2 3 4 5 6 29.00 (1.142) MAX 34.30 (1.350) MAX
CORE TAPED
32.00 (1.260) MAX
UL INSULATION SYMBOL AND MANUFACTURER IDENTIFICATION HERE
1
2
3 5.00 (.197)
4
5
6 4.0 (.157) MIN 22.5 (.886)
REV. 07/18/97 05/20/98 03/05/99 04/20/99 01/06/04
0.8 DIA. (.032)
25.00 (.984)
EI33/29/13 -OR- EI33, 12-PIN VERTICAL BOBBIN UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSIONAL TOLERANCES ARE: DECIMALS ANGLES .X + .25 + 0 O 30' .XX + .15 DO NOT SCALE DRAWING
DESCRIPTION OF CHANGES UPDATED RELEASE ADDED SECOND APPLICATION CIRCUIT FIG. 3B & UL/CSA APPROVALS UPDATED TO UL CLASS (B) INSULATION SYSTEM CHANGED LEAKAGE INDUCTANCE FROM 16.0 MAX TO 12.0 MAX CORRECT PART NUMBER ON PAGE 2 & 3
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FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-30030 REVISION: 01/06/04 DRAWN BY:PETER PHAM REF: PWR-TOP227Y SCALE: NONE SHEET: 1 OF 7
Premier Magnetics POL-30030 Switch Mode Transformer was designed for use with Power Integrations, Inc. PWRTOP204YAI three terminal off-line PWM switching regulator in the Flyback Buck-Boost circuit configuration. This conversion topology can provide isolated multiple outputs with efficiencies up to 90%. Premiers P0L-30030 transformer has been optimized to provide maximum power throughput. The PWR-TOPXXX series from Power Integrations, Inc. are self contained 100KHz three terminal voltage controlled PWM switching regulators. This series contains all necessary functions for an off-line switched mode control DC power source. These switching regulators provide a very simple solution to off-line designs. The inductors and transformer used with the PWR-TOPXXX are critical to the performance of the circuit. They define the overall efficiency, output power and overall physical size. Below is a universal input high precision 90 watt application circuit utilizing Power Integrations PWR-TOP227 switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP227Y & D3 as well as proper thermal management & board layout are critical requirements for efficient and reliable operation. FIGURE 3: TYPICAL APPLICATION CIRCUIT
PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0160 16mHy 1.5A EMI/RFI CMC T1 = POL-30030 MAIN SWITCHING TRANSFORMER L2 = VTP-01002 8uHy@4.0A(10uHY@2.0A) INDUCTOR
F1 3.1A 250v LINE 85-265Vac 50/60Hz NEUT
APPLICATION NOTES
ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: C1: > 400V, Ripple Rated > 790mA @ 120Hz @ Max. Operating Temp. (Nichicon P/N LLQ2G471MHSC, 85C) C2, C3: > 50V, IN PARALLEL Ripple Rated > 3500mA @ 100KHz @ Max. Op. Temp. (Panasonic P/N EEUFA1H102L, 105C)
EMI FILTER 1
C6 0.1uF L1 PMCE-0160 16mHY
BR1 2KBP04M 400V, 2 .0A
2
~
+
HOT RAIL +100 to 375Vdc
C1 470 uF 400V
4
C6 = 0.1uF 250Vac X2-Saftey Cap
3
~
-
C1, 470.0 uF, 400V Nichicon # LLQ2G471MHSC, 85C Diameter=35mm (1.378) Length=40mm (1.575)
+ 1 PRI
T1 POL-30030 VR1 = VR2 1N6298A (1.5KE130A) D1 MUR160 D3 MUR620 L2 VTP-01002 8uH @ 4.0A
1 1/2 OF U3 A C 2
11,12
PROPERLY SIZED HEAT SINK
3 D2 1N4148
4 C
C2,C3 + 1000uF 50V 5 SEC 7,8
+
R3 30.1K 1% R4 2.74K 1%
+30Vdc @ 3.0A + C4 470uF 50V RTN
U3
NEC2501-H
C4 0.1uF
BIAS
U1 POWER INT. TOP227Y
PROPERLY SIZED HEAT SINK
1/2 OF U3
E 3
6
R2 680
DRAIN SOURCE CONTROL
C5 47uF +
R5 390 1W
R1 6.8
KELVIN CONNECT C7 & C8 = 250Vac Y-SAFTEY CAPACITORS EMI FILTER C7 2.2nF C8 2.2nF
SOURCE
U2 1 C TL431 R
A 6 8
C9 0.1uF
HIGH VOLTAGE RETURN
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSIONAL TOLERANCES ARE: DECIMALS ANGLES .X + .25 + 0 O 30' .XX + .15 DO NOT SCALE DRAWING
FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-30030 REVISION: 01/06/04 DRAWN BY:PETER PHAM REF: PWR-TOP227Y SCALE: NONE SHEET: 2 OF 7
APPLICATION NOTES FOR 28.0V @ 4.00A
Below is voltage doubler input high precision 112 watt application circuit utilizing Power Integrations TOP227Y switching regulator in the flyback buck-boost configuration. The component values listed are intended for reference purposes only. Properly sized heat sinks for the TOP227 & D3 as well as proper thermal management of the clamp network are critical requirements for efficient and reliable operation.
PARAMETER FIGURE 3B CIRCUIT PARAMETERS: OUTPUT VOLTAGE OUTPUT CURRENT CONTINUOUS OUTPUT CURRENT PEAK LINE REGULATION (85 TO 132Vac) LOAD REGULATION 10-100% RIPPLE MIN. SPEC LIMITS TYP. 28.0 --------------0.20 0.30 50.0 MAX. UNITS Vdc Amps Amps +% +% +mV
0.50 -----------------------------
4.00 4.20 ----------------------
FIGURE 3B: TYPICAL APPLICATION CIRCUIT
PREMIER MAGNETICS PART NUMBERS: (REQUEST DATA SHEETS BY PART#) L1 = PMCE-0160 16mHy 1.5A EMI/RFI CMC T1 = POL-30030 MAIN SWITCHING TRANSFORMER L2 = VTP-01005 10uHy@5.0A INDUCTOR
ALUMINUM ELECTROLYTIC FILTER CAPACITOR RATINGS: C1: > 400V, Ripple Rated > 740mA @ 120Hz @ Max. Operating Temp. (Nichicon P/N LLQ2G471MHSC, 85C) C2, C3: > 50V, IN PARALLEL Ripple Rated > 3000mA @ 100KHz @ Max. Op. Temp. (Panasonic P/N EEUFA1H102L, 105C)
S1 CLOSED FOR 115V INPUT F1 3.1A 250v LINE 120/220Vac 50/60Hz C1 0.01uF, Y 2 GND C2 0.01uF, Y 2 NEUT C3 0.47uF X2 BR1 DF04M 400V, 1.0A
HOT RAIL +210 to 375Vdc
C5 470 uF 200V
1
R1 300K 1/2W
L1 PMCE-0160 16mHY
+
2
~
C4 0.01uF X2
+
R2 330K
4
3
~
-
R3 330K
C6 470 uF 200V
+
CLAMP NETWORK
T1 POL-30030 1 D3 MUR620 L2 VTP-01005 10uH @ 5.0A
1 1/2 OF U3 A C 2
C15 0.10uF VR1 P6KE200A VR3 P6KE200A D1 MUR160
8K 10W
PRI
11,12
PROPERLY SIZED HEAT SINK
3 D2 1N4148 5
C7 0.1uF
VR2 P6KE200A
C2,C3 + 1000uF 50V SEC 7,8
+
R3 47.3K 1% R4 4.64K 1%
+28Vdc @ 4.0A + C4 470uF 50V RTN
U3
4 C
NEC2501-H U1 POWER INT. TOP 227Y PROPERLY SIZED HEAT SINK
DRAIN SOURCE CONTROL
BIAS
1/2 OF U3
E 3
6
R2 680
C8 47uF +
R5 390 1W
R4 6.2 U2
8
KELVIN CONNECT 1
C TL431 R A 6
C9 0.1uF
HIGH VOLTAGE RETURN
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN MM DIMENSIONAL TOLERANCES ARE: DECIMALS ANGLES .X + .25 + 0 O 30' .XX + .15 DO NOT SCALE DRAWING
FLYBACK TRANSFORMER CONTROL DRAWING PREMIER P/N: POL-30030 REVISION: 01/06/04 DRAWN BY:PETER PHAM REF: PWR-TOP227Y SCALE: NONE SHEET: 3 OF 7

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