
AN-30
27
B
12/02
Appendix C
Introduction
This appendix describes a worked example that shows how to use the 
TOPSwitch-GX
 forward design spreadsheet, to calculate
values for key components, such as the input capacitance, transformer number of turns and duty cycle reduction circuitry, used
on the EP-12 145 W doubled mains prototype board. The design spreadsheet can be found in the 
PIXls
 utility as part of the
PI Expert
 design tool version 4.0.3 and above.
The worked example and spreadsheet uses the same design equations as presented in the design methodology. However, rather
than following the flow chart in the methodology, the worked example follows the order of the spreadsheet. Thus step (a) in
worked example does not correspond to step 1 from AN-30, and so on.
Since the EP-12 has a doubler input stage, the calculations within this document address the design in the doubled mode.
Note that both AN-30 and the design spreadsheet assume single input voltage ranges. Universal input designs are not supported.
Step by Step Example for EP-12
Note: All user inputs are in column B and all calculated results are in column F of the spreadsheet.
Step (a). Enter the Power supply Output specifications: 
V
MAIN 
, I
MAIN 
, V
MAINMA
, I
MAINMA
, V
AUX1
 and 
I
AUX1
Enter the mainwindingoutputvoltage  
V
= 5 V
Enter the main winding full load current  
I
= 12 A
Enter the mag-amp winding output voltage  
V
MAINMA
= 3.3 V
Enter the mag-amp winding full load current  
MAINMA
= 12 A
Enter the auxiliary winding output voltage  
V
AUX1
Enter the auxiliary winding full load current  
AUX1
=  4 A
(IMAIN, B4)
(VMAINMA, B5)
(IMAINMA, B6)
(VAUX1, B7)
(IAUX1, B8)
Step (b). Define system requirements: 
V
ACMAX 
, V
ACMIN 
, f
L
, f
S 
, V
O 
, P
O 
,
η
, t
H
Set minimum AC input voltage = 90 V.
Set maximum AC input voltage = 132 V
Line frequency  
f
 = 50 Hz
Power supply Efficiency Estimate: If no better value available use 75%.
Hold-up time  
t
= 16 ms
Set bridge rectifier conduction time.
If no better value available use default value 
t
C
 = 3 ms
(VACMIN, B14)
(VACMAX,B15)
(fL, B19)
(EFF, B22)
(th, B21)
(tc, B20)
Step (c). Calculation of Minimum and Maximum DC input voltages: 
V
, V
The spreadsheet calculates the maximum DC input voltage, 
V
, at AC high line and minimum DC input voltage 
V
MIN 
, at AC
low line for which the supply remains in regulation under steady state operating conditions.
For the EP-12 prototype, these values are calculated as follows
V
MAX  
= 373 V
V
MIN  
= 188 V
(VMAX, F17)
(VMIN, F16)
Step (d). Determine dropout voltage: 
V
The dropout voltage determines the point where the converter looses regulation, at the end of holdup time, due to reaching
maximum duty cycle.
The dropout voltage, 
V
DROPOUT
,
 and maximum duty cycle are linked. For a higher dropout voltage the designer has to enter a
lower value for 
D
D
MAX_GOAL
.  This ensures the
operating duty-cycle is within an acceptable range.