Design Example Report: Title Specification Application Author Document Number Date Revision

Design Example Report
100 W Refrigeration Power Supply Using

Title
TOP260EN
102 – 265 VAC Input; 12 V, 8 A and
Specification
8 V, 0.4 A Outputs (0 to +40 °C)
Application Appliance
Author Applications Engineering Department
Document
DER-218
Number
Date April 9, 2009
Revision 1.0
Summary and Features

• Typical efficiency (>82%) using TOP260EN
• Meets Class B, EN5022 EMI requirements with 10dB margin
• Low parts count
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits external to the products) 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 grants its customers a license under
certain patent rights as set forth at <http://www.powerint.com/ip.htm>.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
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www.powerint.com
DER-218 12 V, 8 A and 8 V, 0.4 A Power Supply 09-Apr-09
Table of Contents
1 Introduction.................................................................................................................3
2 Power Supply Specification ........................................................................................4
3 Schematic...................................................................................................................5
4 Circuit Description ......................................................................................................6
4.1 Input stage and EMI Filtering...............................................................................6
4.2 TOPSwitch-HX Primary .......................................................................................6
4.3 Output Rectification .............................................................................................6
4.4 Output Feedback.................................................................................................7
5 PCB Layout ................................................................................................................8
6 Bill of Materials ...........................................................................................................9
7 Transformer Specification.........................................................................................11
7.1 Electrical Diagram .............................................................................................11
7.2 Electrical Specification ......................................................................................11
7.3 Materials............................................................................................................11
7.4 Transformer Build Diagram ...............................................................................12
7.5 Transformer Construction..................................................................................12
8 Transformer Design Spreadsheet.............................................................................13
9 Performance Data ....................................................................................................16
9.1 Efficiency ...........................................................................................................16
9.2 No-load Input Power..........................................................................................16
10 Thermal Performance ...........................................................................................17
11 Waveforms............................................................................................................18
11.1 Drain Voltage at 265 VAC Full Load..................................................................18
11.2 Output Voltage Start-up Profile at Zero Load ....................................................18
11.3 Output Voltage Start-up Profile at Full Load ......................................................19
11.4 Output Ripple Measurements............................................................................20
11.4.1 Ripple Measurement Technique ................................................................20
11.4.1 Measurement Results ................................................................................21
12 Control Loop Measurements.................................................................................22
12.1 Low Line (115 VDC) ..........................................................................................22
12.2 High Line (325 VDC) .........................................................................................23
13 Conducted EMI .....................................................................................................24
14 Revision History ....................................................................................................25
Important Note:
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.
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www.powerint.com Page 2 of 26
09-Apr-09 DER-218 12 V, 8 A and 8 V, 0.4 A Power Supply
1 Introduction
This document is an engineering report describing a power supply for an appliance

refrigerator application utilizing TOP260EN (TOPSwitch®-HX family). The power supply
has two outputs: 12 V, 8 A and 8 V, 0.4 A.
This document contains the power supply specification, schematic, bill of materials,
transformer documentation and performance data.
Figure 1 – Populated Circuit Board Photograph.
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2 Power Supply Specification
Description Symbol Min Typ Max Units Comment

Input
Voltage VIN 102 265 VAC 3 Wire system
Frequency fLINE 47 50/60 64 Hz
No-load Input Power (265 VAC) 400 mW
Output
Output Voltage 1 VOUT1 12 V ± 5%
Output Ripple Voltage 1 VRIPPLE1 500 mV 20 MHz bandwidth
Output Current 1 IOUT1 0.0 8 A
Output Voltage 2 VOUT1 8 V ± 5%
Output Ripple Voltage 2 VRIPPLE1 500 mV 20 MHz bandwidth
Output Current 2 IOUT1 0.0 0.4 A
Total Output Power
Continuous Output Power POUT 100 W
Efficiency
Full Load η 82 % Measured at 25 oC
Environmental
Conducted EMI Meets CISPR22B / EN55022B
Designed to meet IEC950, UL1950
Safety Class II
o
Ambient Temperature TAMB 0 40 C Free convection, sea level
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3 Schematic
Figure 2 – Schematic.
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4 Circuit Description
This circuit is a flyback converter for an appliance application using TOP260EN. It is
designed to operate from 102 VAC to 265 VAC. The power supply has two outputs, 12 V
8 A and 8 V 0.4 A, with a total power of up to 100 W. Figure 2 shows the schematic.
4.1 Input stage and EMI Filtering

Fuse F1 protects the power supply against circuit faults such as short circuits. The bridge
rectifier D2 rectifies the AC voltage into DC voltage. Capacitor C4 acts as a filtering
capacitor for the AC rectified waveform and also as the energy storage element for the
power supply.
The Common mode chokes L2, L3 and X-capacitor C16 are placed before the bridge
rectifier to attenuate common mode noise for conducted as well as radiated EMI. The
EMI filter components together with the built in frequency jitter of TOPSwitch-HX help the
power supply meet EMI requirements. Resistors R11, R12 discharge the X-capacitor
within one second after input AC is turned off to prevent shock hazard. Capacitor C7 is a
bypass capacitor which reduces the input voltage loop size.
4.2 TOPSwitch-HX Primary

The clamp snubber circuit consists of D4, R3, VR1, and C9. During turn off of the primary
switching MOSFET, the energy stored in the leakage inductance of the primary winding
of the transformer creates a voltage spike whose voltage level can exceed the
breakdown voltage (VDSS) of the MOSFET. During turn off, diode D5 conducts and TVS
(Transient Voltage Suppressor) VR1 prevents the voltage across the primary winding
from rising above its rated value (200 V in this case).
The rate-of-rise snubber consists of D7, R13, and C17. During turn-off of the MOSFET,
the leakage energy is dumped into the capacitor C17 through D7 and limits dv/dt of the
drain waveform, reducing EMI. The capacitor discharges through R13 at turn-on.
4.3 Output Rectification

There are two outputs for this design.
The 12 V output uses two windings paralleled together with Schottky diodes to increase
efficiency. RC snubbers (R1-C1 and R4-C10) on D1 and D3 provide filtering of the
voltage spike during turn-off of the diodes due to the reverse recovery characteristics and
output leakage inductance which are responsible for significant EMI. Additional factors
such as diode capacitance and trace inductance that affect the turn-off characteristic are
also controlled by this snubber. The post LC filters (L1-C6) at the output reduce ripple.
The 8 V output is a non isolated floating output. It is considered to be on the primary side
despite having a separate return. Regular magnet wire can be used to construct this
output, rather than triple insulated wire. This output is rectified by diode D5 and is
connected to a Low Drop Out (LDO) adjustable linear regulator. Regulator IC U2 is
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adjusted by voltage divider formed by R19 and R20. Capacitors C13 and C14 act as
output filtering capacitors. This output is designed such that the input voltage to U2 is
close to 9 V when both outputs are at full load, reducing the power dissipation in the
linear regulator.
4.4 Output Feedback

The main output is regulated using a TL431 circuit to maintain 5% regulation. The TL431
pulls the current through the photodiode of U3 when the voltage on the reference pin set
by the voltage divider (R7 and R18) goes higher than 2.5 V. Device U1 feeds current into
the CONTROL pin and reduces the duty cycle. An additional soft-finish circuit has also
been implemented using C21, R9, and D8. During startup, C21 charges via U3 providing
feedback prior to the output reaching regulation. This both extends the allowable time for
output to reach regulation (soft-start) and prevents output overshoot. Resistor R9
discharges the soft-finish capacitor during turn off. Capacitor C15 and R15 are
responsible for providing loop compensation. To improve the transient response, phase
margin and the cross over frequency, additional compensation components R21 and C23
are used.
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5 PCB Layout
Figure 3 – PCB Layout.
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6 Bill of Materials
Ref
Item Qty Des Description Mfg Part Number Manufacturer
C1 C10
1 3 C12 1 nF, 100 V, Ceramic, X7R, 1206 Panasonic
2 1 C2 2.2 nF, Ceramic, Y1 Vishay 440LD22-R
3 2 C3 C8 100 nF, 50 V, Ceramic, X7R, 1206 Panasonic ECJ-3VB1H104K
Nippon
4 1 C4 150 µF, 400 V, Electrolytic, Low ESR Chemi-Con EKMX401ELL151ML60S
Nippon
5 2 C5 C11 2200 µF, 25 V, Electrolytic, Very Low ESR Chemi-Con EKZE250ELL222MK35S
Nippon
6 1 C6 1500 µF, 25 V, Electrolytic, Very Low ESR Chemi-Con EKZE250ELL
NIC Components
7 2 C7 C9 3.3 nF, 1 kV, Disc Ceramic Corp NCD332M1KVZ5U
C13 Nippon
8 2 C14 220 µF, 16 V, Electrolytic, Low ESR Chemi-Con ELXZ160ELL221MF15D
C15
C19
9 3 C23 100 nF, 50 V, Ceramic, X7R, 0805 Panasonic ECJ-2YB1H104K
10 1 C16 220 nF, 275 VAC, Film, X2 Panasonic ECQ-U2A224ML
11 1 C17 100 pF, 1 kV, Disc Ceramic Panasonic - ECG ECC-D3A101JGE
Nippon
12 1 C18 10 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) Chemi-Con EKMG500ELL100ME11D
Nippon
13 1 C20 47 µF, 10 V, Electrolytic, Gen. Purpose, (5 x 11) Chemi-Con KME10VB22RM5X11LL
Nippon
14 1 C21 10 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) Chemi-Con KME50VB10RM5X11LL
15 1 C22 1 nF, Ceramic, Y1 Vishay 440LD10-R
16 2 D1 D3 100 V, 20 A, Dual Schotkky, TO-220AB Vishay MBR20100CT
Rectron
17 1 D2 800 V, 8 A, Bridge Rectifier, Glass Passivated Semiconductor GBU8K
18 2 D4 D7 800 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 Vishay MUR160
19 1 D5 60 V, 2 A, Schottky, SMD Vishay SS26
20 1 D6 DIODE ULTRA FAST, SW, 200 V, 1A, SMA Diodes, Inc US1D-13-F
21 1 D8 100 V, 1 A, Ultrafast Recovery, 50 ns, DO-41 Vishay UF4002-E3
22 1 F1 5 A, 250V, Slow, TR5 Wickman 3721500041
23 1 L1 1.5 µH, 8.5 A, 9 x 12 mm JW MIller 6000-1R5M
24 1 L2 6.2 mH, 2.2 A, Common Mode Choke Panasonic ELF20N022A
25 1 L3 CMC, Ferrrite Elytone
R1 R4
26 3 R6 47 Ω, 5%, 1/4 W, Metal Film, 1206 Panasonic ERJ-8GEYJ470V
27 2 R2 R5 2 MΩ, 5%, 1/4 W, Metal Film, 1206 Panasonic ERJ-8GEYJ205V
28 1 R3 100 kΩ, 5%, 1 W, Metal Oxide Yageo RSF100JB-100K
29 1 R7 19.1 kΩ, 1%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6ENF1912V
30 1 R8 1 Ω, 5%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6GEYJ1R0V
31 1 R9 10 kΩ, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-10K
32 2 R10,21 1 kΩ, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-1K0
R11
33 2 R12 1 MΩ, 5%, 1/2 W, Carbon Film Yageo CFR-50JB-1M0
34 1 R13 22 kΩ, 5%, 1/4 W, Metal Film, 1206 Panasonic ERJ-8GEYJ223V
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35 1 R14 390 Ω, 5%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6GEYJ391V

36 1 R15 3.3 kΩ, 5%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6GEYJ332V
37 1 R16 10.5 kΩ, 1%, 1/4 W, Metal Film Yageo MFR-25FBF-10K5
38 1 R17 6.8 Ω, 5%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6GEYJ6R8V
39 1 R18 4.99 kΩ, 1%, 1/4 W, Metal Film, 1206 Panasonic ERJ-8ENF4991V
40 1 R19 Resistor, 200 Ω SMD 0805 Panasonic
41 1 R20 Resistor, 1.07 kΩ SMD 0805 Yageo RC0805FR-07200RL
42 1 T1 Bobbin, EE40, Vertical, 12 pins
Power
43 1 U1 TOPSwitch-HX, TNY260EN, eSIP-7C Integrations TOP260EN
44 1 U2 I.C. Linear regulator, Adjustable TO-220, LDO National LM117
45 1 U3 Optocoupler, 35 V, CTR 300-600%, 4-DIP Sharp PC817X4
46 1 U4 2.495 V Shunt Regulator IC, 2%, 0 to 70C, TO-92 On Semiconductor TL431CLPG
47 1 VR1 200 V, TVS On Semiconductor 1.5KE200A
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7 Transformer Specification
7.1 Electrical Diagram
Figure 4 – Transformer Electrical Diagram.
7.2 Electrical Specification

Electrical Strength 60 Hz 1 second, from pins 1-6 to pins 7-12 3000 VAC
Pins 1 to pin 3, all other windings open,
Primary Inductance 340 µH, ±10%
measured at 100 kHz, 1 VRMS
Resonant Frequency All windings open. 850 kHz (Min.)
Primary Leakage
Pin 1 to pin 3, all other pins shorted. 5 µH (Max.)
Inductance
7.3 Materials
Item Description
[1] 3 mm margin tape
[2] 3M Barrier Tape: polyester film
[3] Core: 1 Pair EE40 TDK PC44 or equivalent
[4] Bobbin: 12 pin EE40, vertical
[5] Magnet Wire: #22 AWG double coated
[6] Magnet Wire: #30 AWG double coated
[7] Triple Insulated Wire: #25 AWG
[8] Copper foil
[9] Varnish
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7.4 Transformer Build Diagram
Figure 5 – Transformer Build Diagram.
7.5 Transformer Construction

Margin tape Wind 3 mm margin on bottom side close to pins.
Start from left to right from Pin 3. Wind 19 turns of 22 AWG wire on one layer.
Primary Winding
Terminate at pin 2.
Insulation Place one layer of tape.
Shield Place one layer of copper foil for shield. Terminate at pin 1.
Insulation Use two layers of tape.
Start from left to right from pin 9 and wind 5 turns of 4x25 AWG Triple-Insulated
Secondary Winding
Wire on one layer. Terminate on pin 10.
Insulation Use one layer of tape.
Start from left to right from pin 11 and wind 5 turns of 4x25 AWG Triple-Insulated
Secondary Winding
Wire on one layer. Terminate on pin 12.
Insulation Use two layers of tape.
Start from left to right from pin 6 and wind 4 turns of 4x30 AWG wire on one layer.
Output winding
Terminate on pin 7.
Insulation Use one layer of tape.
Start from left to right from Pin 5. Wind 6 turns (spread evenly) of 2x30 AWG wire
Bias Winding
on one layer. Terminate on pin 4.
Start from left to right from Pin 2. Wind 19 turns of 22 AWG wire on one layer.
Primary Winding
Terminate at pin 1.
Assembly Assembly and secure core halves.
Flux band Place one turn of shorted copper foil touching the core and terminate to pin 1.
Final Assembly Dip varnish – DO NOT VACUUM IMPREGNATE
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8 Transformer Design Spreadsheet

ACDC_TOPSwitchHX_021308; TOPSwitch-HX
Rev.1.8; Copyright Power Continuous/Discontinuous Flyback
Integrations 2008 INPUT INFO OUTPUT UNIT Transformer Design Spreadsheet
ENTER APPLICATION VARIABLES
VACMIN 102 Volts Minimum AC Input Voltage
VACMAX 265 Volts Maximum AC Input Voltage
fL 50 Hertz AC Mains Frequency
VO 12.00 Volts Output Voltage (main)
PO_AVG 100.00 Watts Average Output Power
PO_PEAK 100.00 Watts Peak Output Power
n 0.80 %/100 Efficiency Estimate
Z 0.50 Loss Allocation Factor
VB 15 Volts Bias Voltage
tC 3.00 mSecond Bridge Rectifier Conduction Time
s Estimate
CIN 150.0 150 uFarads Input Filter Capacitor
ENTER TOPSWITCH-HX VARIABLES
TOPSwitch-HX TOP260EN Universal 115 Doubled/230V
/ Peak
Chosen Device TOP260 Power 200 W / 275W
EN Out 200 W
KI 0.71 External Ilimit reduction factor (KI=1.0
for default ILIMIT, KI <1.0 for lower
ILIMIT)
ILIMITMIN_EXT 3.962 Amps Use 1% resistor in setting external
ILIMIT
ILIMITMAX_EXT 4.558 Amps Use 1% resistor in setting external
ILIMIT
Frequency (F)=132kHz, (H)=66kHz H H Select 'H' for Half frequency - 66kHz,
or 'F' for Full frequency - 132kHz
fS 66000 Hertz TOPSwitch-HX Switching Frequency:
Choose between 132 kHz and 66 kHz
fSmin 59400 Hertz TOPSwitch-HX Minimum Switching
Frequency
fSmax 72600 Hertz TOPSwitch-HX Maximum Switching
Frequency
High Line Operating Mode FF Full Frequency, Jitter enabled
VOR 95.00 Volts Reflected Output Voltage
VDS 10 Volts TOPSwitch on-state Drain to Source
Voltage
VD 0.50 Volts Output Winding Diode Forward
Voltage Drop
VDB 0.70 Volts Bias Winding Diode Forward Voltage
Drop
KP 0.60 Ripple to Peak Current Ratio (0.3 <
KRP < 1.0 : 1.0< KDP<6.0)
PROTECTION FEATURES
LINE SENSING
VUV_STARTUP 114 Volts Minimum DC Bus Voltage at which the
power supply will start-up
VOV_SHUTDOWN 535 Volts Typical DC Bus Voltage at which
power supply will shut-down (Max)
RLS 4.8 M-ohms Use two standard, 2.4 M-Ohm, 5%
resistors in series for line sense
functionality.
OUTPUT OVERVOLTAGE
VZ 27 Volts Zener Diode rated voltage for Output
Overvoltage shutdown protection
RZ 5.1 k-ohms Output OVP resistor. For latching
shutdown use 20 ohm resistor instead
OVERLOAD POWER LIMITING
Overload Current Ratio at VMAX 1.2 Enter the desired margin to current
limit at VMAX. A value of 1.2 indicates
that the current limit should be 20%
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higher than peak primary current at

VMAX
Overload Current Ratio at VMIN 1.06 Margin to current limit at low line.
ILIMIT_EXT_VMIN 3.55 A Peak primary Current at VMIN
ILIMIT_EXT_VMAX 3.61 A Peak Primary Current at VMAX
RIL 8.92 k-ohms Current limit/Power Limiting resistor.
RPL N/A M-ohms Resistor not required. Use RIL resistor
only
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type EI40 EI40 Core Type
Core EI40 P/N: PC40EI40-Z
Bobbin EI40_B P/N: BE-40-1112CPN
OBBIN
AE 1.48 cm^2 Core Effective Cross Sectional Area
LE 7.7 cm Core Effective Path Length
AL 4860 nH/T^2 Ungapped Core Effective Inductance
BW 17.3 mm Bobbin Physical Winding Width
M 1.50 mm Safety Margin Width (Half the Primary
to Secondary Creepage Distance)
L 2.00 Number of Primary Layers
NS 5 5 Number of Secondary Turns
DC INPUT VOLTAGE PARAMETERS
VMIN 96 Volts Minimum DC Input Voltage
VMAX 375 Volts Maximum DC Input Voltage
CURRENT WAVEFORM SHAPE PARAMETERS

DMAX 0.53 Maximum Duty Cycle (calculated at
PO_PEAK)
IAVG 1.31 Amps Average Primary Current (calculated at
average output power)
IP 3.55 Amps Peak Primary Current (calculated at
Peak output power)
IR 2.13 Amps Primary Ripple Current (calculated at
IRMS 1.86 Amps Primary RMS Current (calculated at
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP 340 uHenries Primary Inductance
LP Tolerance 10 Tolerance of Primary Inductance
NP 38 Primary Winding Number of Turns
NB 6 Bias Winding Number of Turns
ALG 236 nH/T^2 Gapped Core Effective Inductance
BM 2148 Gauss Maximum Flux Density at PO, VMIN
(BM<3000)
BP 3034 Gauss Peak Flux Density (BP<4200) at
ILIMITMAX and LP_MAX. Note:
Recommended values for adapters
and external power supplies <=3600
Gauss
BAC 645 Gauss AC Flux Density for Core Loss Curves
(0.5 X Peak to Peak)
ur 2012 Relative Permeability of Ungapped
Core
LG 0.75 mm Gap Length (Lg > 0.1 mm)
BWE 28.6 mm Effective Bobbin Width
OD 0.75 mm Maximum Primary Wire Diameter
including insulation
INS 0.08 mm Estimated Total Insulation Thickness (=
2 * film thickness)
DIA 0.68 mm Bare conductor diameter
AWG 22 AWG Primary Wire Gauge (Rounded to next
smaller standard AWG value)
CM 645 Cmils Bare conductor effective area in
circular mils
CMA 347 Cmils/Am Primary Winding Current Capacity (200
p < CMA < 500)
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Primary Current Density (J) 5.72

Amps/mm Primary Winding Current density (3.8 <
^2 J < 9.75)
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT)
Lumped parameters
ISP 26.99 Amps Peak Secondary Current
ISRMS 13.40 Amps Secondary RMS Current
IO_PEAK 8.33 Amps Secondary Peak Output Current
IO 8.33 Amps Average Power Supply Output Current
IRIPPLE 10.49 Amps Output Capacitor RMS Ripple Current
CMS 2680 Cmils Secondary Bare Conductor minimum
circular mils
AWGS 15 AWG Secondary Wire Gauge (Rounded up
to next larger standard AWG value)
DIAS 1.45 mm Secondary Minimum Bare Conductor
Diameter
ODS 2.86 mm Secondary Maximum Outside Diameter
for Triple Insulated Wire
INSS 0.70 mm Maximum Secondary Insulation Wall
Thickness
VOLTAGE STRESS
PARAMETERS
VDRAIN 566 Volts Maximum Drain Voltage Estimate
(Includes Effect of Leakage
Inductance)
PIVS 61 Volts Output Rectifier Maximum Peak
Inverse Voltage
PIVB 77 Volts Bias Rectifier Maximum Peak Inverse
Voltage
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output
VO1 12.00 12 Volts Output Voltage
IO1_AVG 8.00 8.00 Amps Average DC Output Current
PO1_AVG 96.00 Watts Average Output Power
VD1 0.80 0.8 Volts Output Diode Forward Voltage Drop
NS1 5.12 Output Winding Number of Turns
ISRMS1 12.862 Amps Output Winding RMS Current
IRIPPLE1 10.07 Amps Output Capacitor RMS Ripple Current
PIVS1 62 Volts Output Rectifier Maximum Peak
Inverse Voltage
CMS1 2572 Cmils Output Winding Bare Conductor
minimum circular mils
AWGS1 16 AWG Wire Gauge (Rounded up to next
larger standard AWG value)
DIAS1 1.29 mm Minimum Bare Conductor Diameter
ODS1 2.79 mm Maximum Outside Diameter for Triple
Insulated Wire
2nd output
VO2 9.00 Volts Output Voltage
IO2_AVG 0.40 Amps Average DC Output Current
PO2_AVG 3.60 Watts Average Output Power
VD2 0.40 0.4 Volts Output Diode Forward Voltage Drop
NS2 3.76 Output Winding Number of Turns
ISRMS2 0.643 Amps Output Winding RMS Current
IRIPPLE2 0.50 Amps Output Capacitor RMS Ripple Current
PIVS2 46 Volts Output Rectifier Maximum Peak
Inverse Voltage
CMS2 129 Cmils Output Winding Bare Conductor
minimum circular mils
AWGS2 28 AWG Wire Gauge (Rounded up to next
larger standard AWG value)
DIAS2 0.32 mm Minimum Bare Conductor Diameter
ODS2 3.80 mm Maximum Outside Diameter for Triple
Insulated Wire
Total Continuous Output Power 99.6 Watts Total Continuous Output Power
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9 Performance Data
All measurements performed at room temperature, 60 Hz input frequency.
9.1 Efficiency
85.5
85
Efficiency (%)
84.5
84
83.5
83
82.5
82
81.5
100 125 150 175 200 225 250 275
Vin (VAC)
Figure 6 – Full Load Efficiency vs. Input Voltage.
9.2 No-load Input Power

330
310
Pin (mW)
290
270
250
230
100 125 150 175 200 225 250 275
Vin (VAC)
Figure 7 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.
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10 Thermal Performance
Thermal tests were conducted at worst case condition of 102 VAC with rated load on the
output.
Component Measured at 25 ºC Calculated for 40 ºC

CMC (L2) 82 97
Bridge rectifier 75 90
Bulk capacitor 46 61
TVS Zener 85 100
Snubber clamp diode 81 96
Snubber dv/dt diode 78 93
TOP260EN 89.5 104.5
Transformer 82.2 97.2
Output diode (12 V) 95 110
Output capacitor (12 V) 77 92
Output diode (8 V) 55 70
Output capacitor (8 V) 40 55
CMC (L3) 42 57
Linear regulator
(with heatsink) 60 75
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11 Waveforms
11.1 Drain Voltage at 265 VAC Full Load
Figure 8 – 265 VAC. VDRAIN, 100 V / div, 2.5 µs / div.
11.2 Output Voltage Start-up Profile at Zero Load
Figure 9 – Start-up Profile. No load: 102 VAC, Figure 10 – Start-up Profile. No load: 265 VAC,
5 V / div, 10 ms / div. 5 V / div, 10 ms / div.
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11.3 Output Voltage Start-up Profile at Full Load
Figure 11 – Start-up Profile. Full load: 102 VAC, Figure 12 – Start-up Profile. Full load: 265 VAC,
5 V / div, 10 ms / div. 5 V / div, 10 ms / div.
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11.4 Output Ripple Measurements
11.4.1 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 the figures below.
The 4987BA probe adapter is affixed with two capacitors tied in parallel across the probe
tip. The capacitors include one (1) 0.1 µF/50 V ceramic type and one (1) 1.0 µF/50 V
aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper
polarity across DC outputs must be maintained (see below).
Probe Ground
Probe Tip
Figure 13 – Oscilloscope Probe Prepared for Ripple Measurement. (End cap and ground lead removed)
Figure 14 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter.
(Modified with wires for ripple measurement, and two parallel decoupling capacitors added)
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11.4.1 Measurement Results
Figure 15 – 12 V Ripple, 102 VAC at Full Load. Figure 16 – 12 V Ripple, 265 VAC at Full Load.
50 mV / div, 10 µs / div. 50 mV / div, 10 µs / div.
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
12 Control Loop Measurements
12.1 Low Line (115 VDC)
Figure 17 – Gain Phase Plot, 115 VDC, Full load. Cross Over Frequency: 1.02 kHz Phase Margin: 95°.
Note: The green line indicates oscillator injection level. Normally a higher injection signal is used at low
frequencies. The yellow lines are cursors to indicate gain and phase
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
12.2 High Line (325 VDC)
Figure 18 – Gain Phase Plot, 325 VDC, Full Load. Cross Over Frequency: 3.2 kHz Phase Margin: 95°.
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
13 Conducted EMI
The upper and lower limits shown are quasi peak and the average limits as per EN55022
Class B. A resistive load was connected to DC output terminals. Measurements shown
are peak measurements vs. QP and AVG limits.
RBW 9 kHz
31.Oct 08 14:33 MT 1 s
Att 10 dB AUTO
dBµV 100 1 MHz 10 MHz
90
SGL
1 PK
CLRWR
80
2 AV
CLRWR TDF
70
EN55022Q
60
EN55022A
50
6DB
40
30
20
10
150 kHz 30 MHz
Figure 19 – Conducted EMI, Full Load, 115 VAC, Neutral.
RBW 9 kHz
31.Oct 08 14:34 MT 1 s
Att 10 dB AUTO
dBµV 100 1 MHz 10 MHz
90
SGL
1 PK
CLRWR
80
2 AV
CLRWR TDF
70
EN55022Q
60
EN55022A
50
6DB
40
30
20
10
150 kHz 30 MHz
Figure 20 – Conducted EMI, Full Load, 265 VAC, Neutral.
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
14 Revision History
Date Author Revision Description & changes Reviewed

09-Apr-09 EC, SPM 1.0 Initial Release Apps and Mktg
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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. POWER
INTEGRATIONS MAKES NO WARRANTY 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 transformer construction and circuits external to the products)
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 grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective
companies. ©Copyright 2009 Power Integrations, Inc.
Power Integrations Worldwide Sales Support Locations

WORLD HEADQUARTERS GERMANY JAPAN TAIWAN
5245 Hellyer Avenue Rueckertstrasse 3 Kosei Dai-3 Bldg., 5F, No. 318, Nei Hu Rd., Sec. 1
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chinasales@powerint.com Fax: +82-2-2016-6630 eurosales@powerint.com
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China, 518031 e-mail:
Phone: +86-755-8379-3243 singaporesales@powerint.com
Fax: +86-755-8379-5828
e-mail:
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Design Example Report

100 W Refrigeration Power Supply Using

Summary and Features

This document is an engineering report describing a power supply for an appliance

Figure 1 – Populated Circuit Board Photograph.

2 Power Supply Specification

Description Symbol Min Typ Max Units Comment

4.1 Input stage and EMI Filtering

4.2 TOPSwitch-HX Primary

4.3 Output Rectification

4.4 Output Feedback

Figure 3 – PCB Layout.

35 1 R14 390 Ω, 5%, 1/8 W, Metal Film, 0805 Panasonic ERJ-6GEYJ391V

7.1 Electrical Diagram

Figure 4 – Transformer Electrical Diagram.

7.2 Electrical Specification

7.4 Transformer Build Diagram

Figure 5 – Transformer Build Diagram.

7.5 Transformer Construction

8 Transformer Design Spreadsheet

higher than peak primary current at

CURRENT WAVEFORM SHAPE PARAMETERS

Primary Current Density (J) 5.72

9.2 No-load Input Power

Component Measured at 25 ºC Calculated for 40 ºC

11.1 Drain Voltage at 265 VAC Full Load

Figure 8 – 265 VAC. VDRAIN, 100 V / div, 2.5 µs / div.

11.2 Output Voltage Start-up Profile at Zero Load

11.3 Output Voltage Start-up Profile at Full Load

11.4 Output Ripple Measurements

11.4.1 Ripple Measurement Technique

11.4.1 Measurement Results

12 Control Loop Measurements

12.1 Low Line (115 VDC)

12.2 High Line (325 VDC)

150 kHz 30 MHz

Figure 19 – Conducted EMI, Full Load, 115 VAC, Neutral.

150 kHz 30 MHz

Figure 20 – Conducted EMI, Full Load, 265 VAC, Neutral.

Date Author Revision Description & changes Reviewed

For the latest updates, visit our website: www.powerint.com

Power Integrations Worldwide Sales Support Locations

CHINA (SHANGHAI) INDIA KOREA UNITED KINGDOM

CHINA (SHENZHEN) ITALY SINGAPORE APPLICATIONS HOTLINE

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