EPR-12 Datasheet, PDF (2/40 Pages) Power Integrations, Inc. – Engineering Prototype Report for EP-12 - 145 W PC Forward Converter with TOP247 and 10 W 5 V Output Standby Flyback with TNY266

EPR-12 – PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
Table of Contents
Table of Contents............................................................................................................... 2
1 Introduction ................................................................................................................. 3
2 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
3 Schematics ................................................................................................................. 7
4 Circuit Description ..................................................................................................... 10
5 PCB Layout............................................................................................................... 12
6 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
7 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
8 PIXls Design Spreadsheet ........................................................................................ 25
9 Test Results .............................................................................................................. 30
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
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