
AN-18
A
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DESCRIPTION
Minimum AC Input Voltage
Maximum AC Input Voltage
AC Mains Frequency
TOPSwitchSwitching
 Frequency
Output Voltage
Output Power
Estimated Efficiency
Loss Allocation Factor
Bias Voltage
Bridge Rectifier
Conduction Time Estimate
Input Filter Capacitor (C1)
CELL #
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
APPLICATION VARIABLES
(INPUT TO TABLE 1 AND TABLE 6 SPREADSHEETS)
SYMBOL
V
ACMIN
V
ACMAX
f
L
f
S
V
O
P
O
η
Z
V
B
t
C
C
IN
VALUE
85 VAC
265 VAC
50 Hz
100,000 Hz
12 V
15 W
0.8
0.5
12 V
3 msec
47 
μ
F
SOURCE
Supply Specification
Supply Specification
Supply Specification
AN-16 Default Value
Supply Specification
Supply Specification
AN-16 Default Value
AN-16 Default Value
Supply Specification
AN-16 Default Value
AN-16 Default Value
Table 2. Application Variables for Design Spreadsheets for Figure 1 Power Supply .
The spreadsheets for the two designs diverge at this point. The
following paragraphs will describe completed construction
examples; first for the margin wound design, then the triple
insulated wire design.
Margin Wound Construction Example
In order to carry the margin wound example to completion, the
remainder of the design parameters needed to complete the
Table 1 spreadsheet input section  are described. The construction
example is then completed with the information from the
spreadsheet.
Determining Transformer Construction Variables
In order to complete the input portion of the Table 1 spreadsheet,
information is needed for the transformer/core construction
variable section. Table 4 shows the transformer core/construction
variables chosen for this  margin wound transformer construction
example. The EF25 core is chosen from the transformer core
chart in Appendix A as representative for the power level and
construction type. Dimensional and electrical characteristics
for    the   core   and  a   compatible   bobbin   are   shown   in
Figures 2 and 3.  The core electrical parameters necessary for
the spreadsheet design are A
, L
, and A
, and are loaded into
spreadsheet cells (B24), (B25), and (B26) respectively.  A
margin width (M) of 3 mm (0.118 in) is chosen for the margin
wound design to meet international safety regulations for
universal input voltage range, and loaded into cell (B28). The
number of primary layers (B29) is set at 2 to optimize the core
size and to reduce the transformer leakage inductance and stray
capacitance.
The variable BW (Bobbin Physical Winding Width), required
for the transformer design spreadsheet, represents the width of
the bobbin available for winding. This value can be read directly
from many bobbin specifications. However, in some cases it is
not given directly, and must be calculated from the minimum
total bobbin width and the maximum width of the bobbin end
flanges. The EF25 bobbin drawing shown in Figure 3 does not
show a value for BW.  Instead, the total bobbin width (W
) and
flange width (W
)  are given, including tolerances. BW can be
calculated from these values using the equation:
BW
W
W
T MIN
F MAX
=
×
[
]
)
)
2