
AN-30
30
B
12/02
The spreadsheet also calculates the wire gauge as (AWG-28).
Maximum operating flux density, 
BM
, is the flux density under conditions of full load, and high line. The spreadsheet calculates
and returns this value. Check that this value is less than 2000 gauss.
BM = 1816 gauss
(BM, F74)
Peak flux density is the maximum allowable flux density in the core under transient conditions. This value is also calculated by
the spreadsheet. Check that this value does not exceed 3000 gauss.
BP = 2884 gauss
(BP, F75)
Step (m). Transformer design parameters:
Verify that the maximum and minimum limits of the 
TOPSwitch-GX
 duty-cycle reduction parameters for both high-end and low-
end tolerance parts lie within the reset and regulating limits for any given input voltage.
Reset parameters: 
DMAX
,
DLL
,
DHL
Referring to the curve in Figure 8 these three parameters define the core-reset curve for the transformer.
DMAX
RESET
 = 0.79
DLL
RESET 
= 0.63
DHL
RESET
= 0.36
(DMAX RESET, F145)
(DLL RESET, F152)
(DHL RESET, F157)
Max duty-ratio (Low-end Tolerance part) parameters: 
DXDO
,
DXLL
, DXHL
To ensure correct operation with devices at the higher and lower ends of the maximum duty-ratio, the spreadsheet provides
calculations assuming tolerance limits.
Referring to Figure 8, the parameters with MIN correspond to the parameters for the low-end tolerance part. Duty-ratios
corresponding dropout voltage, low-line input voltage and high line input voltages are listed. These duty-ratios at the
corresponding voltages define the lower limit curves for the maximum duty-cycle reduction circuit. This curve should be above
the 
D
ACTUAL
 curve.
DXDO
MIN
 = 0.70
DXLL
MIN 
= 0.55
DXHL
MIN 
= 0.24
(DXDO MIN, F146)
(DXLL MIN, F150)
(DXHL MIN, F155)
Max duty ratio (High-end tolerance part) parameters: 
DXDO
, 
DXLL
,
DXHL
Again, referring to Figure 8, the parameters with subscripts MAX correspond to the parameters for the high-end tolerance part.
Duty-ratios corresponding dropout voltage, low-line input voltage and high line input voltages are listed. These duty-ratios at the
corresponding voltages define the higher limit curves for the maximum duty-cycle reduction circuit. This curve should be below
the 
D
RESET
 curve.
DXDO
MAX
 = 0.79
DXLL
MAX 
= 0.67
DXHL
MAX
 = 0.35
(DXDO MAX, F147)
(DXLL MAX, F151)
(DXHL MAX, F156)
To guarantee smooth operation, these 4 curves namely the regulation duty cycle (
D
) curve, the low-end tolerance part
(
D
) curve, the high-end tolerance part (
D
 ) curve and the core reset (
D
) curve should never intersect each other. This
guarantees that the power supply will not drop out of regulation and also ensures that there will be no transformer saturation. In
the EP-12 example, the parameter 
DXDO
 exceeds parameter 
DMAX
. This could POSSIBLY cause transformer saturation
ONLY during load transients or during shut down of the converter, which is NOT hazardous.
Regulating duty-ratio parameters: 
DMAX
,
DLL
,
DHL
Referring to Figure 8, these three parameters correspond to the operating duty-ratio at dropout, low line input and high line input
respectively.
DMAX
ACTUAL
 = 0.69
DLL
ACTUAL
DHL
ACTUAL
 = 0.23
(DMAX ACTUAL, F144)
(DLL ACTUAL, F149)
(DHL ACTUAL, F154)