SPECTRA INNOVATIONS INDIA PVT LTD, BANGALORE-43

Schematic Diagram for 5W, DC-DC Psu Design Using TOP264VG device
Customer : GreenTech solution Doc No : SII-EPDVS -1131-0412

CY1

L1 2.2nF,250V,Y1 Cap L2
1mH/150mA D7 3.3uH/1A
R1 C3 8 SB150
1 9V@450mA

1nF,1KV
100K,0.5 W
D1 D2 R2 C7 C8
1N4007 1N4007
240K 470uF/16V
100uF/16V
5

2
RTN
R3
RV1
240K 4

14mm,275VAC D5 D6
F1 D3 D4 FR107 UF4003
1N4007 1N4007 T1 3
2A
EE 13

C6
N
P

C1 10uF/50V R6
AC INPUT C2 330E
22uF/250V
12-150VAC 22uF/250V

1
D V R7
U2 1K
PC817A
U1

2
C
TO P264VG
Note:
1 L2 6X8 Drum Core Inductor
S X F R5
6.8E 2 L3 6X8 Drum Core Inductor
Provide more copper area for source pin for better heatsinking 3 T1 EE13 Ttransformer 4+4 Horizontal
C4
R4 4 C7,C8 105 Deg.
100nF/50V

VR1
18.71K/1% C5 8.2V/500mW Optional for EMI
47uF/16V L1
CY1
C1& C2,any one w ith 47uF is ok
Transformer Design details:
Electrical Diagram

Mechanical Diagram

Winding Instruction
Primary Winding
Start on pin(s) 2 and wind 114 turns (x 1 filar) of item [5] in 3 layer(s) from left to right. At the end of 1st layer, continue to wind the next layer from
right to left. At the end of 2nd layer, continue to wind the next layer from left to right. On the final layer, spread the winding evenly across entire
bobbin. Finish this winding on pin(s) 1.
Add 1 layer of tape, item [3], for insulation.
Bias Winding
Start on pin(s) 4 and wind 17 turns (x 2 filar) of item [5]. Wind in same rotational direction as primary winding. Spread the winding evenly across entire
bobbin. Finish this winding on pin(s) 3.
Add 3 layers of tape, item [3], for insulation.
Secondary Winding
Start on pin(s) 7,8 and wind 12 turns (x 1 filar) of item [6]. Spread the winding evenly across entire bobbin. Wind in same rotational direction as primary
winding. Finish this winding on pin(s) 5,6.
Add 2 layers of tape, item [3], for insulation.
Core Assembly
Assemble and secure core halves. Item [1].
Varnish
Dip varnish uniformly in item [4]. Do not vacuum impregnate.

Comments
1. Pins 7 and 8 are electrically shorted to each other on the PCB via a copper trace.
2. Pins 5 and 6 are electrically shorted to each other on the PCB via a copper trace.
3. For non margin wound transformers use triple insulated wire for all secondary windings.

Materials
Item Description
[1] Core: EE13, NC-2H (Nicera) or Equivalent, gapped for ALG of 144 nH/T²
[2] Bobbin: Generic, 4 pri. + 4 sec.
[3] Barrier Tape: Polyester film [1 mil (25 µm) base thickness], 7.90 mm wide
[4] Varnish
[5] Magnet Wire: 34 AWG, Solderable Double Coated
[6] Magnet Wire: 25 AWG, Solderable Double Coated

Electrical Test Specifications

Parameter Condition Spec
Electrical Strength, VAC 60 Hz 1 second, from pins 1,2,3,4 to pins 5,6. 500
Nominal Primary Inductance, µH Measured at 1 V pk-pk, typical switching frequency, 1863
between pin 1 to pin 2, with all other Windings open.
Tolerance, ±% Tolerance of Primary Inductance 10.0
Maximum Primary Leakage, µH Measured between Pin 1 to Pin 2, with all other Windings 74.53
shorted.