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 Figure 12  shows a split sandwich primary transformer.  The
"noisy" or 
 TOPSwitch
  connected  half  of  the  primary is
wound followed by 1 or 2 tape layers and the bias winding.
To reduce transformer capacitance, 3 to 5tape layers are
placed followed by the secondary.  3 to 5 more tape layers
are placed before winding the "quiet" or V+ connected half
of the primary.
The primary bias winding should be connected directly with a
single trace to the 
TOPSwitch
 Source pin as shown in Figures
7, 8, and 9.  Bias filter capacitor C4 should also connect directly
to the 
TOPSwitch
 Source pin with a single trace.
Auto-restart capacitor C5 should be connected directly across
TOPSwitch
 Control and Source pins to reduce noise voltages on
the Control pin.
Reducing transformer capacitance reduces the peak transient
currents.  To reduce transformer capacitance, the primary must
be properly located relative to the other windings.  3 to 5  layers
of 2 mil thick polyester film tape should also be used between
the secondary and all primary referenced windings. Three
typical transformer design examples are given below:
Figure 10 shows a transformer with single primary
layer, single tape layer and bias winding layer.  To reduce
capacitance, 3 to 5 tape layers are added before the secondary
is wound.
Figure 11. Two-Layer Primary Transformer Cross Section.
PI-1714-120595
Outer Insulation
Primary Bias
3 to 5 Layers Tape
Secondary
3 to 5 Layers Tape
Quiet Primary Half
Basic Insulation
Noisy Primary Half
Figure 11 shows a two layer primary transformer with the
"noisy" or 
TOPSwitch
 connected half of the primary buried
or shielded beneath the "quiet" or V+ connected half of the
primary.  To reduce transformer capacitance, 3 to 5 tape
layers are placed before the secondary is wound.  3 to 5 more
tape  layers  are   placed  over  the secondary  before the
primary bias winding is wound.
PI-1715-120595
Outer Insulation
Quiet Primary Half
3 to 5 Layers Tape
Secondary
3 to 5 Layers Tape
Primary Bias
1 to 2 Layers Tape
Noisy Primary Half
Figure 12. Split Sandwich Primary Transformer Cross Section.
When using triple insulated wire secondaries, the number of
tape layers can be reduced to 1 or 2 layers due to the inherent
spacing and reduced capacitance provided by the insulated
wire.
The highest transformer secondary resistance (smallest wire
diameter) should be used which is still consistent with power
supply efficiency requirements.  Slightly higher secondary
resistance helps limit peak transient currents.
Heat sinks should be either connected only to 
TOPSwitch
 tab or
completely isolated from both 
TOPSwitch 
tab and circuit.  If the
heat sink is connected elsewhere in circuit but isolated from
TOPSwitch
 tab, capacitance between 
TOPSwitch
 tab and heat
sink can resonate with circuit inductance causing high frequency
ringing currents which may trigger 
TOPSwitch
 shutdown latch.
Additional Countermeasures for Differential Mode
Add resistor R6 (approximately 270 to 620 Ohms)  in series
with the optocoupler (U2) phototransistor emitter as shown in
Figures 7, 8, and 9.  R6 limits peak current flow below the
latched shutdown trigger current threshold during output voltage
and control loop overshoot.
Select larger input capacitor C1 to control the final DC bus
voltage.
Carefully select bridge rectifier BR1 (or discrete diodes) for
avalanche and voltage clamping capability.
Select a common mode choke to withstand some excessive
normal mode current levels (occurring when bridge diodes
PI-1713-120595
Outer Insulation
Secondary
3 to 5 Layers Tape
Primary Bias
Basic Insulation
Primary
Figure 10. Single Layer Primary Transformer Cross Section.