IRIStranDC Transformer design Spreadsheet Revision 1.

0 (10/9/01)

International Rectifier Corporation 2001

NOTE: Read AN1024 "Flyback Transformer Design for the IRIS40xx Series
FOR DC Input power supplies

INPUT

NOTES & WARNINGS

OUTPUT

INPUT REQUIRED PARAMETERS

VDCmin
36
Dm
0.5
Cres
220
Fmin
70
0.8

Vo1
5
Iout1
3
Vfd1
0.5
Vcc
18
Vfdvcc
1
Vo2
Vfd2
Iout2
Vo3
Vfd3
Iout3
Vo4
Vfd4
Iout4
Ferrite Core information
Core Type
EFD20
Philips EFD20-3F3
Ae
0.31
Le
4.7
AL
1200
BW
13.2
M
0
L
1
Ns1

UNITS

COMMENTS

Volts

Minimum DC input voltage

Maximum Duty Cycle
Value of resonant capacitor
Minimum operating frequency
Estimated Efficiency (0.7-0.89)
Required Main Output Voltage
Required Main Output Current
Main ouput diode forward voltage
Desired Vcc bias voltage (16-20V)
Bias diode forward voltage
2nd Output Voltage
2nd Output Diode forward voltage
2nd Output Current
3rd Output Voltage
3rd Output Diode forward voltage
3rd Output Current
4th Output Voltage
4th Output Diode forward voltage
4th Output Current

pF
kHz
Volts
Amps
Volts
Volts
Volts
Volts
Volts
Amps
Volts
Volts
Amps
Volts
Volts
Amps

cm^2
cm
nH/turn^2
mm
mm

turns

Effective Cross-sectional Area

Effective Magnetic path length
Inductance Factor
Actual bobbin winding width
Required Safety Margin Width
Number of Primary winding layers
Number of Secondary Turns for main
output

Primary Parameters
Vmin
Po
Iav
Ip
Irms
Transformer Primary
Lp

36 Volts
17.07
0.59
2.37
0.97

W
A
A
A

101 H

Minimum DC input for a DC-DC power

supply
Total Output Power
Average primary current
Peak primary current
RMS primary current

Primary Inductance

Np

33 turns

Number of Primary winding turns

Nb

17 turns

Number of Bias(Vcc) winding turns

ALG

95 nH/turn^2 Effective Inductance factor

Bm

2371 Gauss

Peak Flux Density

BAC
r
lg
BW A
OD
INS
DIA

1185 Gauss
1448
0.38 mm
13.2 mm
0.40 mm
0.06 mm
0.34 mm

AC Flux Density
Relative Permeability of Ungapped Core
Air gap (lg>0.051 for manufacturing)
Available Bobbin Width
Primary wire outside diameter
Primary wire insulation thickness (Est)
Primary wire bare copper diameter

27 AWG

AWG

Primary Wire AWG (nearest larger size)

CM

203 Cirmils

Primary Wire size in Circular Mils

CMAp

210 Cirmils/A

Primary Wire Current Capacity

Transformer Secondaries

5 turns
15.00 A
6.12 A
1286 Cirmils

Ns1
Isp1
Isrms1
CMs1
AWGs1

Nb
CMb
AWGb
Ns2

Err:502

Number of Turns on 1st output

Peak secondary current 1st output
RMS secondary current 1st output
Secondary 1 Wire size in Circular Mils

Err:502 AWG

Err:502

17 turns

Number of Bias winding turns

13 Cirmils

Bias Wire size in Circular Mils

Bias AWG Wire size

Err:502 AWG
0 turns

Number of Turns on 2nd output

Isp2
Isrms2
CMs2

A
A
Cirmils

Peak secondary current 2nd output

RMS secondary current 2nd output
Secondary 2 Wire size in Circular Mils

AWGs2

AWG

Secondary 2 AWG Wire size

Ns3

0 turns

Number of Turns on 3rd output

Isp3
Isrms3
CMs3

A
A
Cirmils

Peak secondary current 3rd output

RMS secondary current 3rd output
Secondary 3 Wire size in Circular Mils

AWGs3

AWG

Secondary 3 AWG Wire size

Ns4

0 turns

Number of Turns on 4th output

Isp4
Isrms4
CMs4

A
A
Cirmils

Peak secondary current 4th output

RMS secondary current 4th output
Secondary 4 Wire size in Circular Mils

AWGs4

AWG

Secondary 4 AWG Wire size

Guidelines for Using the IRIStran Calculation spreadsheet

1. Read the Application Note AN1024a to understand what is important in designing the transformer
2. Decide on a Power Supply specification and input required values in the Red Column
3. Select a ferrite core using the power level guidelines in AN1024a and input the required core information
4. Select a number of turns for the main output
5. Calculated specifications are shown in the Blue Column
6. Watch for warnings in the central column which advise if calculated value are outside of desired limits
7. Comments are included for all the input and output variables to guide you through the design process
8. Calculated Values in Bold typeface are the improtant values required for the transformer specification
9. When you get the warning "wire size too big use multifilar or litz wire" this is not an indication that a redesign is required,
you simply need to get multiple strands of wires to give the same equivalent area e.g. 4 x 26AWG = 1 x 20AWG.
This will minimize the losses in the wire due to the skin effect.

a redesign is required,
1 x 20AWG.