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4

VR1
200 V 5
D1 D3 5 %
1N4007 1N4007
D5
1N4148
F1
1 A
L1
10 mH
C1 C2 R2
195 - 265 2.4 M
10 F 10 F
VAC
450 V 450 V
R1
2.4 M

D
TinySw itch-II EN/UV
D2 D4 U1 BP
1N4007 1N4007 T NY268PN
S C
0.
5
C4
1 nF
250 VAC

T1
E25/13/7 (
4 10
6.0 V, 1.20 A
D8 C7
VR1 UF5404 1000 F
200 V 25 V
5 9
5 % RTN
8
D5 15.0 V, 0.30 A
1N4148 D7 C6
UF4005 100 F
7 25 V
GND1
C5
R2
D6 100 F
.4 M UF4005 25 V
6
-15.0 V, 0.30 A
R1
.4 M

D
ch-II EN/UV
BP U2A R3
8PN LT V817A 270
S C3 U2B VR2
0.1 F
LT V817A 5.1 V
50 V
2 %
.0 V, 1.20 A

TN

5.0 V, 0.30 A

GND1

15.0 V, 0.30 A
Power Supply Input
Var Value Units
VACMIN 195 V
VACMAX 265 V
FL 50 Hz
TC 1.97 ms
Z 0.54
74 %
IAVG 0.09 A
VMIN 241.8 V
VMAX 374.8 V

Input Section and EMI Filter


Var Value Units
Fuse 1A
Input Rectifier 1N4007
CIN1 10 F
CIN2 10 F
LCM 10 mH
CY 1 nF

Device Variables
Var Value Units
Device TNY268PN
PO 16.2 W
VDRAIN Estimated 612.24 V
VDS 3.78 V
FSMIN 120000 Hz
KP 0.97
ILIMITMIN 0.51 A
ILIMITMAX 0.59 A
CBP 0.1 F
RLS 2.4 M
RLS2 2.4 M
IRMS 0.19 A
P_NO_LOAD 300 mW
DMAX 0.36
RTH_DEVICE 106.54 C/W
DEV_HSINK_TYPE 2 Oz (70 ) Copper PCB
DEV_HSINK_AREA 52 mm

Clamp Components
Var Value Units
DB 1N4148
VCLAMP 200 V
VRZ P6KE200A
Estimated Clamp Loss 0.72 W

Transformer Construction Parameters


Var Value Units
Core Type E25/13/7 (EF25)
Core Material NC-2H (Nicera) or Equivalent
Bobbin Reference Generic, 5 pri. + 5 sec.
Bobbin Orientation Vertical
Primary Pins 4
Secondary Pins 5
LPmin 1226 H
LP_Tol 10 %
LP_nom 1362 H
NP 70.1
NSM 4
CMA 1062 Cmils/A
VOR 135 V
BW 15.3 mm
ML 0 mm
MR 0 mm
FF 38 %
AE 52.5 mm
ALG 249 nH/T
BM 2088 Gauss
BAC 871 Gauss
LG 0.227 mm
L_LKG 40.9 H
LSEC 15 nH

Primary Winding Section 1


Var Value Units
NP1 71
Wire Size 27 AWG
Winding Type Single (x1)
L 1.9
DC Copper Loss 0.02 W
PIN_S 5
PIN_T 4

Output 1
Var Value Units
VO 15 V
IO 0.3 A
VOUT_ACTUAL 13.7 V
NS 8
Wire Size 30 AWG
Winding Type Single (x1)
L_S_OUT 0.24
DC Copper Loss 0.04 W
Start Pin(s) 8
Termination Pin(s) 7
VD 1.7 V
PIVS 56 V
ISP 1 A
ISRMS 0.47 A
DO UF4005
RTH_DIODE 107.14 C/W
OD_HSINK_TYPE 2 Oz (70 ) Copper PCB
OD_HSINK_AREA 52 mm
CO 100 x 1 F
IRIPPLE 0.36 A
Expected Lifetime 18555 hr

Output 2
Var Value Units
VO -15 V
IO 0.3 A
VOUT_ACTUAL -13.7 V
NS 8
Wire Size 30 AWG
Winding Type Single (x1)
L_S_OUT 0.24
DC Copper Loss 0.04 W
Start Pin(s) 7
Termination Pin(s) 6
VD 1.7 V
PIVS 56 V
ISP 1 A
ISRMS 0.47 A
DO UF4005
RTH_DIODE 107.14 C/W
OD_HSINK_TYPE 2 Oz (70 ) Copper PCB
OD_HSINK_AREA 52 mm
CO 100 x 1 F
IRIPPLE 0.36 A
Expected Lifetime 18555 hr

Output 3
Var Value Units
VO 6 V
IO 1.2 A
VOUT_ACTUAL 6 V
NS 4
Wire Size 27 AWG
Winding Type Bifilar (x2)
L_S_OUT 0.29
DC Copper Loss 0.09 W
Start Pin(s) 10
Termination Pin(s) 9
VD 1.7 V
PIVS 27 V
ISP 3.99 A
ISRMS 1.87 A
DO UF5404
RTH_DIODE 28.61 C/W
OD_HSINK_TYPE 2 Oz (70 ) Copper PCB
OD_HSINK_AREA 1671 mm
CO 1000 x 1 F
IRIPPLE 1.44 A
Expected Lifetime 61882 hr

Feedback Circuit
Var Value Units
Rated Voltage 5.1 V
Zener Test Current 5 mA
RF1 270

The regulation and tolerances do not account for thermal drifting and component tolerance of the out
Please verify cross regulation performance on the bench.
Description
Minimum Input AC Voltage
Maximum Input AC Voltage
Line Frequency
Diode Conduction Time
Loss Allocation Factor
Efficiency Estimate
Average Diode Bridge Current (DC Input Current)
Minimum DC Input Voltage
Maximum DC Input Voltage

Description
Input Fuse Rated Current
Recommended Input Diodes/Diode Bridge (Manual Input)
Input Bulk Capacitor (Manual Input)
Input Bulk Capacitor (Manual Input)
Common Mode Choke (Manual Input)
Y-Capacitor (Manual Input)

Description
PI Device Name (Manual Input)
Total Output Power
Actual Estimated Drain Voltage
On state Drain to Source Voltage
Minimum Switching Frequency
Continuous/Discontinuous Operating Ratio
Current Limit Minimum
Current Limit Maximum
Device bypass capacitor
Line sense resistor
Line sense resistor
Primary RMS Current (at VMIN)
Estimated No Load Input Power
Maximum Duty Cycle
PI Device Maximum Thermal Resistance
PI Device Heatsink Type
PI Device Heatsink Area

Description
Recommended Blocking Diode (Manual Input)
Estimated average clamping voltage
Recommended Zener Clamp
Clamp Dissipation

Description
Core Type (Manual Input)
Core Material
Bobbin Reference
Bobbin type
Number of Primary pins used
Number of Secondary pins used
Minimum Primary Inductance
Primary Inductance Tolerance
Nominal Primary Inductance
Calculated Primary Winding Total Number of Turns
Secondary Main Number of Turns
Primary Winding Current Capacity
Reflected Output Voltage
Bobbin Winding Width
Safety Margin on Left Width
Safety Margin on Right Width
Actual Transformer Fit Factor. 100% signifies fully utilized winding window
Core Cross Sectional Area
Gapped Core Effective Inductance
Maximum Flux Density
AC Flux Density for Core Loss
Estimated Gap Length
Estimated primary leakage inductance
Secondary Trace Inductance

Description
Rounded (Integer) Number of Primary winding turns in the first section of primary
Wire size of primary winding
Primary winding number of parallel wire strands
Primary Number of Layers
Primary 1 DC Losses
Starting pin(s) for first section of primary winding (Manual Input)
Termination pin(s) for first section of primary winding (Manual Input)

Description
Output Voltage
Output Current
Actual Output Voltage
Secondary Number of Turns
Wire size of secondary winding
Output winding number of parallel strands
Secondary Output Winding Layers
Secondary DC Losses
Starting pin(s) for Output winding (Manual Input)
Termination pin(s) for Output winding (Manual Input)
Output Winding Diode Forward Voltage Drop (Manual Input)
Output Rectifier Maximum Peak Inverse Voltage
Peak Secondary Current
Secondary RMS Current
Recommended Output Diode (Manual Input)
Output Diode Maximum Thermal Resistance
Output Diode Heatsink Type
Output Diode Heatsink Area
Output Capacitor
Output Capacitor RMS Ripple Current
Expected Lifetime of Output Capacitor

Description
Output Voltage
Output Current
Actual Output Voltage
Secondary Number of Turns
Wire size of secondary winding
Output winding number of parallel strands
Secondary Output Winding Layers
Secondary DC Losses
Starting pin(s) for Output winding (Manual Input)
Termination pin(s) for Output winding (Manual Input)
Output Winding Diode Forward Voltage Drop (Manual Input)
Output Rectifier Maximum Peak Inverse Voltage
Peak Secondary Current
Secondary RMS Current
Recommended Output Diode (Manual Input)
Output Diode Maximum Thermal Resistance
Output Diode Heatsink Type
Output Diode Heatsink Area
Output Capacitor
Output Capacitor RMS Ripple Current
Expected Lifetime of Output Capacitor
Description
Output Voltage
Output Current
Actual Output Voltage
Secondary Number of Turns
Wire size of secondary winding
Output winding number of parallel strands
Secondary Output Winding Layers
Secondary DC Losses
Starting pin(s) for Output winding (Manual Input)
Termination pin(s) for Output winding (Manual Input)
Output Winding Diode Forward Voltage Drop (Manual Input)
Output Rectifier Maximum Peak Inverse Voltage
Peak Secondary Current
Secondary RMS Current
Recommended Output Diode (Manual Input)
Output Diode Maximum Thermal Resistance
Output Diode Heatsink Type
Output Diode Heatsink Area
Output Capacitor (Manual Input)
Output Capacitor RMS Ripple Current
Expected Lifetime of Output Capacitor (Manual Input)

Description
Zener Rated Voltage (Manual Input)
Zener Test Current (Manual Input)
Zener Biasing resistor

onent tolerance of the output diode forward voltage drop and voltage drops across the LC post filter. The actual
post filter. The actual voltage values are estimated at full load only.
Bill Of Materials

Item # Quantity Part Ref Value DescriptionMfg Mfg Part Number


1 2 C1, C2 10 F 10 F, 450 United Che EKMX450VB10RM12X25LL
2 1 C3 0.1 F 0.1 F, 50 Murata RPER71H104K2P1A03B
3 1 C4 1 nF 1 nF, 250 VVishay 440LD10-R
4 2 C5, C6 100 F 100 F, 25 United Che KZE25VB101MF11LL
5 1 C7 1000 F 1000 F, 25United Che KZE25VB102MK20LL
6 4 D1, D2, D3 1N4007 1000 V, 1.0Vishay 1N4007
7 1 D5 1N4148 75 V, 0.30 Vishay 1N4148
8 2 D6, D7 UF4005 600 V, 1.00Vishay UF4005
9 1 D8 UF5404 400 V, 3.00Vishay UF5404
10 1 F1 1:00 AM 265 VAC, 1 Littelfuse 3.7E+010
11 1 L1 10 mH 10 mH, 1 A Tokin SC-01-E100G
12 2 R1, R2 2.4 M 2.4 M, 5 %Generic
13 1 R3 270 270 , 5 %,Generic
14 1 T1 E25/13/7 ( NC-2H (NiceEpcos B66317-G-X127
15 1 U1 TNY268PN TinySwitch-Power IntegTNY268PN
16 1 U2 LTV817A OptocouplerLiteon LTV817A
17 1 VR1 P6KE200A 200 V, 5 W Vishay P6KE200A
18 1 VR2 BZX79-B5V5.1 V, 500 Vishay BZX79-B5V1
19 1 52 mm areaCustom
20 1 52 mm areaCustom
21 1 52 mm areaCustom
22 1 1671 mm arCustom
10RM12X25LL
K2P1A03B
Electrical Diagram

Mechanical Diagram

Winding Instruction
Primary Winding
Start on pin(s) 5 and wind 71 turns (x 1 filar) of item [5] in 2 layer(s) from left to right. At the end of 1
Add 3 layers of tape, item [3], for insulation.
Secondary Winding
Start on pin(s) 8 and wind 8 turns (x 1 filar) of item [6]. Spread the winding evenly across entire bobb
Add 1 layer of tape, item [3], for insulation.
Start on pin(s) 7 and wind 8 turns (x 1 filar) of item [7]. Spread the winding evenly across entire bobb
Add 1 layer of tape, item [3], for insulation.
Start on pin(s) 10 and wind 4 turns (x 2 filar) of item [6]. Spread the winding evenly across entire bob
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. For non margin wound transformers use triple insulated wire for all secondary windings.

Materials
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]

Electrical Test Specifications


Parameter
Electrical Strength, VAC
Nominal Primary Inductance, H
Tolerance, %
Maximum Primary Leakage, H

Although the design of the software considered safety guidelines, it is the user's responsibility to ensu
The products and applications illustrated herein (including circuits external to the products and transf
Description
Core: E25/13/7 (EF25), NC-2H (Nicera) or Equivalent, gapped for ALG of 249 nH/t
Bobbin: Generic, 5 pri. + 5 sec.
Barrier Tape: Polyester film [1 mil (25 m) base thickness], 15.30 mm wide
Varnish
Magnet Wire: 27 AWG, Solderable Double Coated
Triple Insulated Wire: 30 AWG
Triple Insulated Wire: 27 AWG

Condition Spec
60 Hz 1 sec 3000
Measured at 1362
Tolerance o 10
Measured be 40.9
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