EPR-12 [POWERINT]
Engineering Prototype Report for EP-12 - 145 W PC Forward Converter with TOP247 and 10 W 5 V Output Standby Flyback with TNY266; 对于EP- 12工程原型报告 - 145 W¯¯ PC正激变换器TOP247和10 W 5 V输出反激式待机与TNY266型号: | EPR-12 |
厂家: | Power Integrations |
描述: | Engineering Prototype Report for EP-12 - 145 W PC Forward Converter with TOP247 and 10 W 5 V Output Standby Flyback with TNY266 |
文件: | 总40页 (文件大小:1498K) |
中文: | 中文翻译 | 下载: | 下载PDF数据表文档文件 |
Engineering Prototype Report for EP-12 -
145 W PC Forward Converter with TOP247 and
10 W 5 V Output Standby Flyback with TNY266
Title
Specification
Application
Author
PC Main and PC Standby
PI Applications
Document
Number
EPR-12
01-Feb-05
1.3
Date
Revision
Objective
This document describes the operation and provides the performance data of a design
using TOP247 as a forward converter for 145 W PC supply application and TNY266 as a
10 W flyback for PC standby.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
Applications Hotline: Tel: +1 408 414 9660 Fax: +1 408 414 9760
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EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
Table of Contents
Table of Contents............................................................................................................... 2
1
2
Introduction ................................................................................................................. 3
Supply Requirements.................................................................................................. 5
2.1 Power Supply Specification..................................................................................... 5
2.2 Conditions for Cross Regulation Test...................................................................... 6
2.3 Output Characteristics............................................................................................. 6
2.4 Transient Overshoot................................................................................................ 6
2.5 Short Circuit Protection............................................................................................ 6
Schematics ................................................................................................................. 7
Circuit Description..................................................................................................... 10
PCB Layout............................................................................................................... 12
Bill Of Materials......................................................................................................... 14
6.1 Electrical Bill of Materials....................................................................................... 14
6.2 Hardware Bill of Materials...................................................................................... 16
6.3 Output Cable Bill of Materials................................................................................ 16
6.4 Heatsinks Bill of Materials ..................................................................................... 17
Transformer Specification......................................................................................... 18
7.1 145 W Forward Transformer ................................................................................. 18
7.1.1 Electrical Specifications.................................................................................. 18
7.1.2 Materials......................................................................................................... 18
7.1.3 Transformer Build Diagram ............................................................................ 19
7.1.4 Transformer Construction............................................................................... 19
7.2 10 W PC Standby Transformer ............................................................................. 21
7.2.1 Electrical Specifications.................................................................................. 21
7.2.2 Materials......................................................................................................... 21
7.2.3 Transformer Build Diagram ............................................................................ 22
7.2.4 Transformer Construction............................................................................... 22
7.3 Output Coupled Inductor ....................................................................................... 23
7.3.1 The Toroid Layout.......................................................................................... 23
7.3.2 Inductances.................................................................................................... 23
7.4 The Mag Amp Inductor.......................................................................................... 24
7.4.1 Core Specification .......................................................................................... 24
7.4.2 Winding Instruction......................................................................................... 24
PIXls Design Spreadsheet ........................................................................................ 25
Test Results.............................................................................................................. 30
3
4
5
6
7
8
9
10 Performance Data..................................................................................................... 31
10.1 Efficiency and Regulation .................................................................................. 31
10.2 Power Limit vs. Input Line.................................................................................. 32
11 Waveforms................................................................................................................ 33
11.1 Drain Switching Waveforms............................................................................... 34
11.2 Output Ripple Measurements ............................................................................ 36
12 Conducted EMI ......................................................................................................... 37
13 Revision History ........................................................................................................ 38
Power Integrations
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Page 2 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
Important Note:
Although the EP-12 is designed to satisfy safety isolation requirements, this
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.
Power Integrations
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Page 3 of 40
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EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
1
Introduction
The following engineering report gives the detailed description and test data for a
TOP247 forward converter designed for 145 W PC main applications and a TNY266
flyback for PC standby. The requirements listed below are typical of a PC power supply.
Figure 1 - EP-12 Populated Circuit Board.
Power Integrations
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Page 4 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
2
Supply Requirements
2.1 Power Supply Specification
Description
Symbol
Min
Typ
Max
Units
Comment
Input
Doubler Input
Voltage
Frequency
Standby Input Power (115 VAC)
Blue Angel Input Power (240 VAC)
VIN
fLINE
90
47
115
50/60
0.91
4.2
132
63
1
VAC
Hz
W
0.5 W Output From Standby
2.5 W output From Standby
5
W
Output
4%
Output Voltage 1
Output Ripple Voltage 1
Output Current 1
Output Voltage 2
Output Ripple Voltage 2
Output Current 2
VOUT1
VRIPPLE1
IOUT1
VOUT2
VRIPPLE2
IOUT2
3.17
3.30
5.00
3.43
50
12
5.25
50
15
V
mV
A
V
mV
A
20 MHz Bandwidth
0.5
4.75
5%
20 MHz Bandwidth
0.4
7%
Output Voltage 3
Output Ripple Voltage 3
Output Current 3
Output Voltage 4 (standby)
Output Ripple Voltage 4
Output Current 4
VOUT3
VRIPPLE3
IOUT3
VOUT4
VRIPPLE4
IOUT4
11.16 12.0 12.84
120
V
mV
A
V
mV
A
20 MHz Bandwidth
5 A, 15 s Surge
5%
0.05
4.75
3
5.25
50
5.00
20 MHz Bandwidth
2.5 A, 15 s Surge
0
2.0
Total Output Power
Continuous Output Power (main)
Continuous Output Power (s/b)
PO_main
PO_s/b
150
10
175
12.5
W
W
Efficiency
Measured at PO_main =150 W
Meets CISPR22B / EN55022B
Main Converter
65
71
%
ηmain
Environmental
Conducted EMI
Designed to Meet IEC950,
UL1950 Class II
Safety
1.2/50 µs Surge, IEC 1000-4-5,
12 Ω Series Impedance,
Differential and Common Mode
Surge
4
kV
100 kHz Ring Wave, 500 A Short
Circuit Current, Differential and
Common Mode
Surge
4
0
kV
oC
Free Convection, Sea Level
Ambient Temperature
TAMB
50
Power Integrations
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Page 5 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
2.2 Conditions for Cross Regulation Test
Load
+5 V
11 A
15 A
2 A
0.4 A
5 A
15 A
12 A
0 A
+3.3 V
12 A
7 A
2 A
0.5 A
3 A
7 A
12 A
0 A
+12 V
3 A
3 A
3 A
0.05 A
1 A
3 A
5 A (15 s)
0 A
1
2
3
4
5
6
7
8
2.3 Output Characteristics
a. Rise time: all outputs of the power supply must rise from 10% to 90% of their rated
output voltages within 2 ms to 20 ms at nominal line, maximum load.
b. Turn-on delay time: 1000 ms maximum at nominal line, full load.
c. Hold-up time: 16 ms minimum for all outputs at 110 VAC, 60 Hz, and full load.
2.4 Transient Overshoot
a. +5 V, +12 V and +3.3 V dynamic load transient response. Transient response is
measured by switching the output load from 80% to 100% to 80% of its maximum
load, other outputs are under maximum load with an input voltage from 90 VRMS to
132 VRMS and at a frequency of 100 Hz and 50% duty cycle, step load change is
0.5 A/µs. The peak transient amplitude is less than or equal to +5% / -5% of +5 V,
+12 V, +3.3 V output. The recovery time is less than 5 ms.
b. Overshoot: +5 V: 5.5 V maximum
+3.3 V: 3.63 V maximum
2.5 Short Circuit Protection
The main supply shall latch off from a shorted output condition. The latch is reset through
toggling remote ON/OFF.
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Page 6 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
3
Schematics
Figure 2 – EP-12 Main Forward Converter Primary Side.
Power Integrations
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Page 7 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
Figure 3 - EP-12 Main Forward Converter Secondary Side.
Power Integrations
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Page 8 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
Figure 4 – EP-12 Standby Flyback Converter.
Figure 5 – EP-12 Remote ON / OFF Interface.
Power Integrations
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Page 9 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
4 Circuit Description
With line feed forward, duty factor reduction, programmable primary current limit, line-
sense for input UV and OV, and soft-start function for smooth start-up, the
TOPSwitch−GX family has all the needed functions to operate in an off-line, single-
ended forward converter configuration. Also the TOPSwitch−GX family has a sufficient
power capability to bring PC main applications easily within its reach.
In the present design the LINE-SENSE pin (L pin, please refer to TOPSwitch−GX data
sheet) senses the rectified DC input voltage through the combination of R3, R5, and R6
and inhibits the supply from switching until the minimum voltage of 80 VAC (doubled
mains) or 160 VAC is reached. Upon reaching this voltage and activation of switching,
current sourced from R8 will immediately establish a maximum duty factor limit by
injecting the appropriate amount of current into the LINE-SENSE pin (adjusting maximum
duty factor, please refer to TOPSwitch−GX data sheet). The input from R8 is a quasi-
integrated, DC-rectified forward voltage sourced from the bias winding and will restrict
the duty factor to a greater degree as the line voltage is increased. This is a very
significant function to ensure that the transformer will not saturate, even in extreme
transient load conditions.
A TOP247 was selected for this 145 W application and its primary current limit was
adjusted to limit at approximately 2.5 A by R12 when U3 is on. This allows approximately
170 W of peak output power.
Lowering the input voltage will cause the converter to shut off by means of the under-
voltage lockout circuit around Q1. When input voltage is low enough to bias on Q1, the
collector of Q1 will pull up the X pin of the TOP247 via R39 and shut off the main
converter.
This design uses a Zener primary clamp (D3, D4, D5) with a capacitor (C4) in parallel
that is coupled to the drain of the TOPSwitch−GX through a diode (D1). This is a very
efficient snubber as it allows the maximum flyback voltage to develop during the off time
which returns a significant amount of energy back to the transformer during the reverse
time recovery of the diode D1. The total dissipation of the primary snubber clamp circuit
was measured to be only 0.8 W at maximum load.
It is necessary to use voltage mode control in the regulation loop when using
TOPSwitch−GX. As the data will show, the transient response is very good and there
appears to be no difficulty in compensating the voltage mode control loop for optimal
performance.
The remote ON/OFF function is implemented by using a very simple circuit around Q3.
When the ON line (green wire in output cable) is grounded to secondary return, Q3 is
turned on and drives the LED of U3 on, which will ground R12 on the primary side and
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Page 10 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
enable the TOP247 via its X pin. If the output comes up into regulation before C19
completely discharges, Q3 is sustained on through R28 and the converter remains
running. Upon loss of regulation, Q3 will turn off and the converter will shut off. Toggling
the ON/OFF input will allow the converter to retry operation.
When the ON line is open, it is internally pulled up to the +5 V standby and the main
converter remains in the inhibit state. The +5 V standby is always operating provided
there is sufficient AC input to the supply. By connecting the ON line to output return, the
main supply will turn on, provided there is sufficient input voltage and there is no fault
condition. If there is a fault then the supply will latch off. A retry is accomplished by
simply toggling the ON line.
Note: If the remote ON line is connected to output return (main power enabled) while
turning on AC into the supply, the main converter will automatically turn on. However, if
AC is brought up too slowly (i.e. adjusting a variac), the supply will not turn on and the
ON line will have to be toggled to turn on the supply. The output interconnect board
provided has the ON line already connected to an ON/OFF switch for manual
ON/OFF control via the ON line.
Power Integrations
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Page 11 of 40
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EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
5
PCB Layout
Figure 6 – EP-12 Assembly Diagram.
Power Integrations
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Page 12 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
Figure 7 – EP-12 Top View.
Power Integrations
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Page 13 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
6
Bill Of Materials
6.1 Electrical Bill of Materials
Item Qty Reference
Part Number
KBL06
Manufacturer
Gen. Semi.
Description
KBL06
1
2
3
4
5
6
7
8
1
1
1
1
2
2
2
1
1
2
7
BR1
CX1
CX2
CY1
CY4, CY3
C3, C2
C102, C4
C5
C19
C6
ECQ-U2A104ML
ECQ-U2A334MG
440LQ47
ECK-ATS222ME
200AXW330MK1835
200 pF, 1000 V, Y5P, 10%
ECA-2AHG010
ECA-1CHG220
ECA-1CHG470
ECU-S1H104MEA
Panasonic
Panasonic
Vishay/Sprague
Vishay/Sprague
Rubycon
0.1 µF, 250 VAC
0.33 µF, 250 VAC
47 pF, 1 kV (Safety)
2.2 nF(Safety)
330 µF, 200 V
2.2 nF, 1 kV
Xicon
Panasonic
Panasonic
Panasonic
Panasonic
1 µF, 100 V
9
10
11
22 µF, 16 V
47 µF, 16 V
C7, C13, C14,
C18, C103, C107
C8, C23
C9
0.1 µF, 50 V
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
2
1
1
1
2
2
1
1
1
1
2
1
1
2
2
2
1
2
1
3
2
1
2
1
1
1
9
ECU-S1H333MEA
K473K15X7RF5TL2
ECU-S1H102JCB
EEU-FC1C102
EEU-FC0J222
ECA-1AFQ122
ECU-S1H331JCA
ECA-2AHG2R2
ECU-SIH101JCA
10,000 pF, 500 V, Y5P, 10%
ECA-1AFQ102L
ECA-1AH6471
1N5407
BZY97C-180
BAV20
MBR2045CT
MBR3045WT
UF4002-1
1N5228B-D7
Panasonic
BC Components 0.047 µF, 50 V
0.033 µF
C10
C11
C15, C12
C16, C17
C20
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Xicon
Panasonic
Panasonic
Diodes Inc.
Philips
Diodes Inc.
Int. Rect.
Int. Rect.
Fagor
Gen. Semi.
Diodes Inc.
Philips
0.001 µF, 50 V
1000 µF, 16 V
2200 µF, 6.3 V
1200 µF, 10 V
330 pF, 50 V
2.2 µF, 100 V
100 pF, 50 V
0.01 µF, 500 V
1000 µF, 10 V
470 µF, 10 V
1N5407
BZY97C-180
BAV20
MBR2045
MBR3045
UF4002
C21
C22
C101
C104, C105
C106
D1
D4, D5
D6, D18
D7, D9
D8
D11, D10
D12
1N5228
1N4148
BZX79-C B4V3
1N4006
BZY97-C200
1N5822
D13, D104, D105 1N4148-T
D14, D19
D101
1N4006G-T
BZY97-C200
1N5822
3721400041
Sleeving (Alpha TFT250 #18) Alpha
Diodes Inc.
Philips
Gen Semi
Wickmann
D3, D102
D103
F1
4 A
JP9 Sleeving
JP2, JP3, JP4,
JP5, JP6, JP7
Insulation/Sleeving
JUMPER
(cut from wire roll)
Belden
8019 000 #18
JP8, JP9, JP10, JP11
39
40
41
42
43
44
45
1
2
1
1
1
1
1
L1 coupled choke 13 µH/15 A
L5, L2
L3
DT Magnetics
Prem Mag
DT Magnetics
J.W. Miller
Panasonic
TOKO
13 µH
SPE-119-0
0.5 µH
Mag amp
20 µH, 12 A
8.2 mH
10 µH, 2 A
2N3906
L4
5702
L7
L101
Q1
ELF-18D650C
R622LY-100K
TO-92 Transistor/PNP
Power Integrations
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Page 14 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
Item Qty Reference
Part Number
Manufacturer
Description
TIP32C
2N3904
MPSA42
MPSA92
10 Ω
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
2
1
Q2
Q3, Q7
Q4
Q6
RT1
RV1
R1, R2
R3
R4
R6
R7
R8
R5
R9
R10
R39
R12
R13
R14
R15
R16, R23, R35
R31, R17
R18
R19
R20
R21
R22
R24
R25
R26
R11, R27
R28, R33
R29,
R30
R32
R34
TO-220 Power Transistor/PNP
TO-92 Transistor/NPN
TO-92 transistor/PNP 300 V
TO-92 transistor/NPN 300 V
RL3004-6.56-59-S7
ERZ-V14D431
Keystone
Panasonic
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
Yageo
DT Magnetics
275 V, 14 mm
330 kΩ
CFR-25JB-330k
CFR-25JB-2M2
CFR-25JB-2M2
CFR-25JB-2M2
CFR-25JB-560K
MFR-25FBF-130K
CFR-25JB-180K
CFR-25JB-47R
CFR-50JB-560K
CFR-25JB-3K3
CFR-25JB-7K5
CFR-25JB-10R
CFR-25JB-75K
CFR-25JB-1K8
CFR-25JB-1K0
CFR-25JB-15K
CFR-25JB-4K64
CFR-25JB-4K12
CFR-25JB-150K
CFR-25JB-270R
CFR-25JB-3R0
CFR-25JB-3K48
CFR-25JB-2K2
CFR-25JB-10K
CFR-25JB-390R
CFR-25JB-4K7
CFR-25JB-100K
RSF100JB-1R0
CFR-25JB-27K
CFR-25JB-33R
MFR-25FBF-43K2
CFR-25JB-10K
CFR-25JB-51R
CFR-25JB-4M0
CFR-25JB-430R
CFR-25JB-5k1
2.2 MΩ
2.2 MΩ
2.2 MΩ
560 kΩ
130 kΩ, 1%
180 kΩ
47 Ω
560 kΩ, 1/2 W
3.3 kΩ
7.5 kΩ
10 Ω
75 kΩ
1.8 kΩ
1 kΩ
15 kΩ
4.64 kΩ, 1%
4.12 kΩ, 1%
150 kΩ, 1%
270 Ω
3 Ω
3.48 kΩ, 1%
2.7 kΩ
10 kΩ
390 Ω
4.7 kΩ
100 kΩ
1 Ω, 1 W
27 kΩ
33 Ω
43.2 kΩ, 1%
10 kΩ
51 Ω
1 MΩ, 1%
430 Ω
5.1 kΩ
27 kΩ
PC Main
Transformer
PC Standby
Transformer
TOP247Y1
SFH615A-2
LTV817
TL431
R36
R37
R101
R103, R102
R104
R105, R38
R106
T1
CFR-25JB-27K
EER-28L
1
90
1
T101
EE-16
DT Magnetics
91
92
93
94
95
1
1
2
2
1
U1
U2
U102, U3
U6, U5
U101
TOP247Y1
SFH615A-2
LTV817
TL431
TNY266P
Power Integrations
Sharp
Power Integrations
TNY266P
Power Integrations
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Page 15 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
6.2 Hardware Bill of Materials
Item Qty Reference
Description
PCB, Assembly Main
P/N
DAK-12
Manufacturer
Power
1
1 ea PCB, Main
Integrations
N/A
2
1 kit Enclosure/Hardware
Top & Bottom
N/A
Enclosure, Fan,
Fan Screws (2 ea),
AC Input Conn,
Voltage Selection Switch
Conn, Spade
3
4
5
6
7
8
1 ea Conn, Spade
2 ea Cap
31887
AMP
16-22 AWG, #10 PIDG
Cap, 470 pF, 20%
250 V, Ceramic Y2/X1
Wire, Grn/Yel, 18 AWG
UL1015, Pretinned
Wire, Wht, 18 AWG
UL1015, Pretinned
Wire, Blk, 18 AWG
UL1015, Pretinned
Wire, Wht, 22 AWG
UL1015, Pretinned
Tie Wrap, 4", Nylon
Screw, M3 X 5 mm
Screw, #6 X ¼
ECK-ATS471MB Panasonic
2.5” N/A
Any
Any
4”
4”
N/A
N/A
1015-18/1-0
Any
Any
12” N/A
9
10
11
4 ea N/A
2 ea N/A
7 ea N/A
PLT1M
PANDUIT
Any
Any
6N25PPBZZ
Pan Head, Type B,
Self Tap, Zinc Pltd
Insulator, Fishpaper Rev D
12
1 ea N/A
6.3 Output Cable Bill of Materials
Item Qty Reference
Description
P/N
Manufacturer
1
1 ea P2
Recp, 2 X 10
4.2 mm Mini-Fit Jr
39-01-2205
(94V-0)
MOLEX
2
17 ea N/A
Terminal, Crimp, Fem
AWG 18-24, Tin
39-00-0039
MOLEX
3
4
5
6
7
8
9
70” N/A
30” N/A
30” N/A
10” N/A
10” N/A
10” N/A
4 ea Conn A, B, C, F
Wire, Blk, 18 AWG, UL 1015
Wire, Red, 18 AWG, UL 1015
Wire, Org, 18 AWG, UL 1015
Wire, Yel, 18 AWG, UL 1015
Wire, Grn, 22 AWG, UL 1015
Wire, Vio, 22 AWG, UL 1015
Conn, Wire Pin
Any
Any
Any
Any
Any
Any
MOLEX
19211-0001
11-01-0197
Term 10-12 AWG
Tool, Hand Crimper
10
Tool
MOLEX
Mini-Fit Jr. 18-24 AWG
Tool, Extraction Mini-Fit Jr
Tool, Hand Crimper
11
12
Tool
Tool
11-03-0044
19285-0063
MOLEX
MOLEX
Wire Pin Term (Molex 19211-0001)
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Page 16 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
6.4 Heatsinks Bill of Materials
Item Qty Part Reference
Description
P/N
Manufacturer
1
2
3
4
5
6
7
8
1
1
4
1
1
4
4
1
Fab, H.S. Primary, EP-12 Rev. D
Fab, H.S. Secondary, EP-12 Rev. C
Scr, Phil Pan, M3 X 8, Stl, Znc
Scr, Phil Pan, M3 X 10, Stl, Znc
Wshr, Split Lock, M3
Wshr, Shldr, #4 [M2, 5]
Sil-Pad 600, Heatsink, TO-220
Sil-Pad TO-3P Heatsink, TO-247
U1, D7, D9, Q2
D8
U1
U1, D7, D9, Q2
U1, D7, D9, Q2
D8
Olander Co.
Olander Co.
Olander Co.
Keystone
Berquist
Berquist
3049
BER102
BER109
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Page 17 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
7
Transformer Specification
7.1 145 W Forward Transformer
Figure 8 - EP-12 145 W Forward Transformer.
7.1.1Electrical Specifications
Electrical strength
Primary Inductance
Resonant Frequency
Primary leakage inductance
60 Hz, 1 min, from Pins 1-7 to Pins 10-14
All windings open
3000 VAC
4.5 mH or Higher
0.2 MHz minimum
8 µH maximum
All windings open
Pins 6-14 shorted
7.1.2Materials
Item
Description
Core: PC40 EER28L
Bobbin: BEER28L-1114CPH
[1]
[2]
Magnet Wire: #28 AWG Heavy Nyleze
Magnet Wire: #30 AWG Heavy Nyleze
Magnet Wire: #20 AWG Heavy Nyleze
Copper ribbon .670″ x .008″
Tape: 3M 1298 Polyester Film (white) 21.8 mm wide by 2.2 mils thick
Tape: 3M 1298 Polyester Film (white) 15.8 mm wide by 2.2 mils thick
Tape: 3M 44 Margin tape (cream) 3.0 mm wide by 5.5 mils thick
[3]
[4]
[5]
[6]
[7]
[8]
[9]
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Page 18 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
7.1.3 Transformer Build Diagram
Figure 9 – EP-12 145 W Forward Transformer Build Diagram.
7.1.4Transformer Construction
Margin Taping
Primary Winding
Basic Insulation
Margin Taping
Use item [9] for the right and left margins.
Start at pin 5. Wind 45 turns of item [3] from left to right. Wind
uniformly in a single layer. End at pin 1.
1 Layer of tape [8] for basic insulation.
Use item [9] for the right and left margins.
Start at pin 3. Wind trifilar 6 turns of item [4] from left to right.
Wind uniformly in a single layer, across entire width of bobbin.
Finish on pin 7.
Bias Winding
Reinforce Insulation
3 Layers of tape [7] for insulation.
Prepare copper ribbon [6] as shown in Figure 10. Match pin A
of the foil to pin 11 or 12 of the bobbin. Wind 3 turns of item
[6]. Finish by matching pin B of the foil to pins 8 and 9 of the
bobbin.
Copper Foil Winding
(5 V)
Reinforce Insulation
Margin Taping
3 Layers of tape [7] for insulation.
Use item [9] for the right and left margins.
Start at pin 13. Wind 4 turns of item [5] from left to right. Wires
are populated in middle of bobbin. Finish at pin 14.
3 Layers of tape [7] for insulation.
12 V Winding
Outer Insulation
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Page 19 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
Figure 10 – +5 V Foil (measurements are in mm).
Figure 11 – +5 V Foil and Tape.
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Page 20 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
7.2
10 W PC Standby Transformer
Figure 12 - EP-12 10 W Standby Transformer.
7.2.1Electrical Specifications
Electrical Strength
Primary Inductance
Resonant Frequency
1 min, 60 Hz, from pins 1-4 to pins 5-10
All windings open
All windings open
3000 VAC
2.3 mH
800 kHz minimum
Primary Leakage Inductance
Pins 6-10 shorted
130 µH maximum
7.2.2Materials
Item
Description
Core: EE16
Bobbin: BE-16
Magnet Wire: #35 AWG Heavy Nyleze
Triple Insulated Wire: #26 AWG
Magnet wire #30 AWG heavy Nyleze
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Tape: 3M 1298 Polyester Film (white) 9.0 mm wide by 2.2 mils thick
Varnish
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Page 21 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
7.2.3 Transformer Build Diagram
01-Feb-05
Figure 13 - EP-12 10 W Standby Transformer Build Diagram.
7.2.4Transformer Construction
Start at Pin 7. Wind 158 turns of item [3] from left to right, then from right to left
until done. It takes about 3 1/4 layers. Apply 1 layer of tape, item [5] between each
winding layer for basic insulation. Finish the wiring on Pin 5.
Primary Layer
Insulation
Bias Winding
Insulation
1 Layer of tape [6] for insulation.
Start at pin 9. Wind 17 turns of item [5] from left to right. Finish on pin 10.
1 Layer of tape [6] for insulation.
Start at Pin 2. Wind 7 bifilar turns of item [4] from left to right. Wind uniformly, in a
single layer, across entire width of bobbin. Finish on Pin 1.
3 Layer of tape [6] for insulation.
Secondary Winding
Outer Insulation
Final Assembly
Assemble and secure core halves. Impregnate uniformly [7].
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Page 22 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
7.3 Output Coupled Inductor
7.3.1The Toroid Layout
Figure 14 - The Side View.
Figure 15 - Bottom Plate Viewed from Top.
(Measurements are in inches).
(Measurements are in inches).
Figure 16 – EP-12 Inductor.
7.3.2 Inductances
Pin #
6-1
5-2
AWG #
18
Color
Red
Red
# of Turns
Inductance (µH)
13 20%
12
12
16
18
18
13 20%
23 20%
3-4
Natural
Note:
1
2
All dimensions are 0.02”
Core = T 106 – 26
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Page 23 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
7.4 The Mag Amp Inductor
7.4.1Core Specification
Figure 17 – EP-12 Core Measurements.
Figure 18 – EP-12 Core.
Core Number
MP1305P-4AS
OD
14.4 mm
ID
7.9 mm
HT
6.6 mm
7.4.2Winding Instruction
Use number 18 AWG wire (heavy gauge Nyleze wire) to wind 7 turns around the
core as shown in Figure 18. Leave the wire legs about 1″ long.
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Page 24 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
8
PIXls Design Spreadsheet
ACDC_TOPGXForward_Rev_1.03_061
802 Copyright Power Integrations Inc. INPUT
2002
ACDC_TOPGXFwd_061802_r103.xls:
TOPSwitch-GX Forward Transformer
Design Spreadsheet
INFO
OUTPUT
UNIT
OUTPUT VOLTAGE AND CURRENT
EP12 PC Main power supply
Main output voltage
VMAIN
5
Volts
IMAIN
12
3.3
12
12
4
Amps
Volts
Amps
Volts
Amps
Volts
Amps
Main output current
VMAINMA
IMAINMA
VAUX1
IAUX1
VIND1
IND1
Magamp output voltage
Magamp output current
Auxiliary output voltage
Auxiliary output current
Independent output voltage
Independent output current
Total output power
PO
147.6 Watts
ENTER APPLICATION VARIABLES
Minimum AC input voltage. Input voltage
doubler circuit is assumed.
VACMIN
90
AC volts
Maximum AC input voltage. Input voltage
doubler circuit is assumed.
VACMAX
132
AC volts
188 Volts
373 Volts
uFarads
Hz
VMIN
Minimum DC Bus voltage at low line input
Maximum DC Bus voltage at high line input
VMAX
Equivalent bulk input capacitance. Input
voltage doubler circuit is assumed.
CIN
165
fL
tc
50
Input AC line frequency
3.0
mSeconds Estimate input bridge diode conduction time
Minimum required hold-up time from
VDROPOUT to VHOLDUP
Efficiency estimate to determine minimum
DC bus voltage
th
16.0
0.75
mSeconds
EFF
DC Bus voltage at start of hold-up time
(default VMIN)
VHOLDUP
188 Volts
VDROPOUT
DMAX GOAL
VDSOP
132
0.7
132 Volts
0.70
DC Bus Voltage at end of hold-up time
Maximum duty cycle at DC dropout voltage
Maximum operating drain voltage
580 Volts
Maximum output current ripple factor at
maximum DC Bus voltage
KDI
0.15
Enter one ("1") for DC stacked, zero ("0")
Independent winding
REF AUX1
1
DC Stack
ENTER TOPSWITCH VARIABLES
TOPSwitch
Chosen Device
ILIMIT
top247
TOP247
Universal
Doubled 115V/230V
Power Out
-
165 W
3.348 3.852
Amps
Hertz
From TOPSwitch-GX datasheet
From TOPSwitch-GX+H76 datasheet
fS
124000 132000
limit reduction (KI=1.0 for default ILIMIT, KI
<1.0 for lower ILIMIT)
KI
0.81
Maximum current limit resistance to ensure
KI >= 0.81 setting
RX
7.78 kOhm
2.712 Amps
8.1 Volts
ILIMITEXT
VDS
External current limit
TOPSwitch-GX average on-state Drain to
Source Voltage
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Page 25 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
DIODE Vf SELECTION
Main output rectifiers forward voltage drop
(Schottky)
Magamp output rectifiers forward voltage
drop (Schottky)
Auxiliary output rectifiers forward voltage
drop (Ultrafast)
VDMAIN
0.5 Volts
0.5 Volts
0.7 Volts
VDMAINMA
VDAUX1
Independent output rectifiers forward voltage
drop (Schottky)
VDIND1
VDB
0 Volts
0.7 Volts
Bias output rectifier conduction drop
BRIDGE RECTIFIER DIODE
SELECTION
Maximum voltage across Bridge rectifier
diode
VPIVAC
IDAVBR
467 Volts
0.773 Amps
Average Bridge Rectifier Current
TRANSFORMER CORE SELECTION
Core Type
eer28l
Core
EER28L
P/N:
P/N:
PC40EER28L-Z
EER28L_
BC
Bobbin
BEER-28L-112CPH
AE
LE
0.814 cm^2
7.55 cm
Core Effective Cross Sectional Area
Core Effective Path Length
AL
BW
2520 nH/T^2
21.8 mm
Ungapped Core Effective Inductance
Bobbin Physical Winding Width
Maximum actual gap when zero gap
specified
LG MAX
0.02 mm
Percentage of total PS losses lost in
transformer windings; default 10%
R FACTOR
9%
3.0
9% %
mm
M
Transformer margin
L
0.80
Transformer primary layers
Main rounded turns
NMAIN
3
TRANSFORMER DESIGN
PARAMETERS
NP
45
45
6
Primary rounded turns
Bias turns to maintain 8V minimum input
voltage, light load
NB
Auxiliary rounded turns (DC stacked on
Main winding)
NAUX1
4
Approx. Aux output voltage with NASUX1 =
4 Turns and DC stack
Independent rounded turns (separate
winding)
VAUX1 ACTUAL
NIND1
11.63 Volts
0
Approximate independent output voltage
with NIND1 = 0 turns
VIND1 ACTUAL
0.00 Volts
Maximum operating flux density at minimum
switching frequency
Maximum peak flux density at minimum
switching frequency
BM
1816 Gauss
2884 Gauss
BP
Minimum primary magnetizing inductance
(assumes LGMAX=20um)
LP MIN
3.419 mHenries
Peak magnetizing current at minimum input
voltage
IMAG
0.189 Amps
0.33 mm
OD_P
AWG_P
Primary wire outer diameter
Primary Wire Gauge (rounded to maximum
AWG value)
28 AWG
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Page 26 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
CURRENT WAVESHAPE
PARAMETERS
Maximum peak primary current at maximum
DC Bus voltage
IP
2.451 Amps
Maximum primary RMS current at minimum
DC Bus voltage
IPRMS
1.460 Amps
INDUCTOR OUTPUT PARAMETERS
Main / Auxiliary coupled output inductance
(referred to Main winding)
LMAIN
10.0 uHenries
Main / Auxiliary coupled output inductor full-
load stored energy
WLMAIN
KDIMAIN
2286 uJoules
0.150
Current ripple factor for Magamp output
LMAINMA
12.3 uHenries
888 uJoules
0.150
Magamp output inductance
Magamp output inductor full-load stored
energy
WLMAINMA
KDIMAINMA
Current ripple factor for Magamp output
LIND1
0.0 uHenries
0.0 uJoules
0.000
Independent output inductance
Independent output inductor full-load stored
energy
WLIND1
KDIIND1
Current ripple factor for independent output
SECONDARY OUTPUT PARAMETERS
Maximum transformer secondary RMS
current (DC Stack)
Maximum transformer secondary RMS
current (DC Stack)
Maximum transformer secondary RMS
current (DC Stack)
ISMAINRMSLL
15.61 Amps
2.42 Amps
0.00 Amps
ISAUX1RMSLL
ISIND1RMSDLL
Maximum average current, Main rectifier
(single device rating)
Maximum average current, Magamp rectifier
(single device rating)
Maximum average current, Auxiliary rectifier
(single device rating)
Maximum average current, Independent
rectifier (single device rating)
IDAVMAIN
IDAVMAINMA
IDAVAUX1
IDAVIND1
12.3 Amps
9.3 Amps
3.1 Amps
0.0 Amps
Maximum RMS current, Main output
capacitor
Maximum RMS current, Magamp output
capacitor
Maximum RMS current, Auxiliary output
capacitor
Maximum RMS current, Independent output
capacitor
IRMSMAIN
IRMSMAINMA
IRMSAUX1
IRMSIND1
0.52 Amps
0.52 Amps
0.17 Amps
0.00 Amps
DIODE PIV
No derating
VPIVMAIN
29.5 Volts
29.5 Volts
Main output rectifiers peak-inverse voltage
Magamp output rectifiers peak-inverse
voltage
Auxiliary output rectifiers peak-inverse
voltage
VPIVMAINMA
VPIVAUX1
34.9 Volts
Independent output rectifiers peak-inverse
voltage
VPIVIND1
VPIVB
0.0 Volts
102.1 Volts
Bias output rectifier peak-inverse voltage
Optocoupler
VCEO OPTO
49.8 Volts
Maximum optocoupler collector-emitter
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Page 27 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
voltage
UNDER-VOLTAGE LOCKOUT CIRCUIT
PARAMETERS
AC undervoltage lockout voltage; On-Off
transition
AC undervoltage lockout voltage; Off-On
transition
VACUVL
VACUV
68 AC volts
78 AC volts
VACUVX
RUVA
68
2.23 MOhm
523.73 kOhm
75.91 kOhm
Resistor RUVA value
Resistor RUVB value
Resistor RUVC value
RUVB
RUVC
Actual AC undervoltage lockout voltage; On-
Off transition
Actual AC undervoltage lockout voltage; Off-
On transition
VACUVL ACTUAL
VACUVX ACTUAL
67.50 AC volts
70.36 AC volts
DUTY CYCLE LIMIT CIRCUIT PARAMETERS
VZ
6.80 Volts
Zener voltage used within DLIM circuit
Approximate frequency reduction voltage
(determines CVS value)
VOV
380 Volts
RA
2.20 MOhm
2.20 MOhm
40.26 kOhm
126.70 kOhm
92.98 pF
Resistor RA value
Resistor RB value
Resistor RC value
Resistor RD value
Capacitor CVS value
RB
RC
RD
CVS
DUTY CYCLE PARAMETERS (see
graph)
Dropout Duty-Cycle Parameters
Operating Duty cycle at DC Bus dropout
voltage
Transformer Reset Minimum duty cycle at
DC Bus dropout voltage
Device Min Duty cycle limit at DC Bus
dropout voltage
!!! >DMASRESET from VMIN to
VDROPOUT. NOT hazardous
DMAX ACTUAL
DMAX RESET
DXDO MIN
0.69
0.79
0.70
0.79
DXDO MAX
Caution
DLL ACTUAL
DXLL MIN
0.47
0.55
0.67
0.69
Duty cycle at minimum DC Bus voltage
Duty cycle minimum limit at minimum DC
Bus voltage
Duty cycle maximum limit at minimum DC
Bus voltage
Minimum duty cycle to reset transformer at
low line
DXLL MAX
DLL RESET
High Line Duty-Cycle Parameters
DHL ACTUAL
DXHL MIN
0.23
0.24
Duty cycle at minimum DC Bus voltage
Duty cycle minimum limit at maximum DC
Bus voltage
Duty cycle maximum limit at maximum DC
Bus voltage
DXHL MAX
0.35
Minimum duty cycle to reset transformer at
high line
DHL RESET
0.36
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Page 28 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
DX_MAX
D_RESET
D_ACTUAL
DX_MIN
Figure 19 – PIXls Duty Cycle Reduction Parameters Chart.
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Page 29 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
9
Test Results
Thermal and Dissipation Data
TOP247 dissipation at 90 VAC and 5 V at 15 A, 3.3 V at 7 A, 12 V at 4 A (approximately
140 W) was measured 5.4 W.
The unit was enclosed in a standard ATX enclosure. The ambient external temperature
around the enclosure was 25 °C and the internal ambient in the enclosure in the box
near TOP247 heatsink was measured 37 °C.
The TOP247 source tab temperature for above conditions was measured 53 °C.
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Page 30 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
10 Performance Data
10.1 Efficiency and Regulation
Output Current
Output Voltage
Pin
Efficiency
Load Input VAC
+5 V
(A)
0.4
0.4
0.4
0.4
15
+12 V +3.3 V +5 VSB +5 V
+12 V +3.3 V +5 VSB
(A)
0.05
0.05
3
(A)
0.5
12
(A)
0
(V)
5.09
5.07
5.11
5.1
(V)
(V)
(V)
(W)
10
1
2
132
132
132
132
90
12.02
11.92
11.6
3.31
3.21
3.29
3.23
3.28
3.2
5.05
4.89
4.84
5.1
43%
71%
77%
72%
76%
74%
77%
71%
73%
64%
67%
74%
2
72
3
0.5
12
2
62
4
3
0
11.54
12.41
12.45
11.95
11.92
11.93
103
114
154
146
223
217
3.9
20
5
0.05
0.05
3
0.5
12
2
5
4.8
6
90
15
0
5
5.07
5.13
4.86
4.83
4.87
4.87
4.87
7
90
15
0.5
12
0
5.02
4.99
4.99
3.28
3.2
8
90
15
3
2
9
115
230
115
115
15
3
12
2
3.21
10
11
12
0.5
2
0.4
15
0.0168
1.9690
0.5
12
5.1
12.1
3.33
3.2
2
4.99
12.03
198
Note: 12 V load table does not include the 100 mA internal load, which is equivalent to
fan loading.
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Page 31 of 40
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EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
10.2 Power Limit vs. Input Line
Total Output Power (Watts) at Threshold
of Over Power Shutdown
179
178
177
176
175
174
173
172
171
90
100
110
120
130
140
AC Input (Volts)
Figure 20 – Power Limit vs. Input Line.
Standby Input Power
The input power with standby loaded to 0.5 W and main supply off at 115 VAC input is
0.91 W.
Note: when measuring for less than 1 W input power spec and output interconnect board
is used, the yellow standby on LED on the board dissipates 0.07 W. This should be
considered part of the output loading.
Blue Angel
240 VAC input, main converter inhibited, +5 V standby loaded to 2.5 A.
Input power is 4.2 W.
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Page 32 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
11 Waveforms
+ 5 V output
3.3 V Output
0.5 A/div
Figure 21 – Primary Drain Current at Start-up,
Activated from Remote ON/OFF
with 120 VAC Input.
Figure 22 – +5 V and 3.3 V Rise at Turn-on from
Remote ON/OFF , 120 VAC Input,
5 V out at 12 A, 3.3 V at 12 A,
0 A on +12 V.
5 V Standby
5 V Main
5 V Standby
5 V Main
Figure 23 – 5 V Main and 5 V Standby Start-up
Figure 24 – 5 V and 5 V Standby Drop out After
AC off Max Load on 5 V Standby, Min
Load on all Other Outputs.
(120 VAC). Max Load on all Outputs.
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Page 33 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
11.1 Drain Switching Waveforms
5 V @ 12 A, 3.3 V @ 12 A, 12 V @ 3 A
Figure 25 – Drain to Source Voltage of TOP247
Figure 26 – Drain to Source Voltage of TOP247
at 165 VAC.
at 220 VAC.
Figure 27 – Drain to Source Voltage of TOP247
Figure 28 – Drain to Source Voltage of TOP247
at 270 VAC Input 3.3 V Output
Shorted at PC Board.
at 270 VAC.
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Page 34 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
5 V Standby
5 V Output
Input Line Current
Figure 30 – Drain Switching Voltage of TNY266
(PC Standby) 230 VAC Input
Figure 29 – 110 VAC Applied Line Terminated
with Following Loads: 5 V at 13 A,
3.3 V at 12 A, 12 V at 3.5 A.
5 V Loaded to 1.5 A.
Figure 31 – 5 V Step Load (8 A/15 A)
Maximum Continuous Load
on Other Outputs.
Figure 32 – 3.3 V Step Load 6 A/12 A.
+ 5 V Standby Output
Step Load 0.3 A to 1.5 A
Figure 33 – +5 V Standby Step Load Response.
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Page 35 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
11.2 Output Ripple Measurements
Output ripple measured with following load:
12 V @ 3 A, 5 V @ 12 A, 3.3 V @ 12 A, 5 V standby @ 2 A.
Figure 34 – +12 V Output Ripple.
Figure 35 – +5 V Output Ripple.
Figure 36 – +3.3 V Output Ripple.
Figure 37 – +5 V Standby Output Ripple.
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Page 36 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
12 Conducted EMI
Figure 38 – 230 VAC, Neutral Input, Maximum Load on all Outputs.
Figure 39 – 230 VAC Line Input, Maximum Load on all Outputs.
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Page 37 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
13 Revision History
Date
Author
Revision Description & Changes
09-Jul-02
AO
1.0
1.1
1.2
First release
Corrected schematic on page 8 and
caption on Figure 22
30-Aug-02
21-Oct-02
AO
AO
Corrected Figure 11
Corrected 7.2.1 Primary Inductance on
page 21 and added missing Part
Numbers on page 15
01-Feb-05
AO
1.3
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Page 38 of 40
01-Feb-05
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
Notes
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Page 39 of 40
EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
For the latest updates, visit our website: www.powerint.com
Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any
information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER
INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES
INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
PATENT INFORMATION
The products and applications illustrated herein (including 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.
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Power Integrations. PI Expert and PI FACTS are trademarks of Power Integrations. © Copyright 2005 Power Integrations.
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Page 40 of 40
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