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Engineering Prototype Report for EP-12 145 W PC Forward Converter with TOP247 and 10 W 5 V Output Standby Flyback with TNY266
Specification Application Author Document Number Date Revision PC Main and PC Standby PI Applications EPR-12 01-Feb-05 1.3
Objective This document describes the operation and provides the performance data of a design using TOP247 as a forward converter for 145 W PC supply application and TNY266 as a 10 W flyback for PC standby.
Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 Applications Hotline: Tel: +1 408 414 9660 Fax: +1 408 414 9760 www.powerint.com
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
Table of Contents Table of Contents............................................................................................................... 2 1 Introduction ................................................................................................................. 3 2 Supply Requirements.................................................................................................. 5 2.1 Power Supply Specification ..................................................................................... 5 2.2 Conditions for Cross Regulation Test...................................................................... 6 2.3 Output Characteristics ............................................................................................. 6 2.4 Transient Overshoot ................................................................................................ 6 2.5 Short Circuit Protection............................................................................................ 6 3 Schematics ................................................................................................................. 7 4 Circuit Description ..................................................................................................... 10 5 PCB Layout............................................................................................................... 12 6 Bill Of Materials......................................................................................................... 14 6.1 Electrical Bill of Materials....................................................................................... 14 6.2 Hardware Bill of Materials...................................................................................... 16 6.3 Output Cable Bill of Materials ................................................................................ 16 6.4 Heatsinks Bill of Materials ..................................................................................... 17 7 Transformer Specification ......................................................................................... 18 7.1 145 W Forward Transformer ................................................................................. 18 7.1.1 Electrical Specifications.................................................................................. 18 7.1.2 Materials......................................................................................................... 18 7.1.3 Transformer Build Diagram ............................................................................ 19 7.1.4 Transformer Construction............................................................................... 19 7.2 10 W PC Standby Transformer ............................................................................. 21 7.2.1 Electrical Specifications.................................................................................. 21 7.2.2 Materials......................................................................................................... 21 7.2.3 Transformer Build Diagram ............................................................................ 22 7.2.4 Transformer Construction............................................................................... 22 7.3 Output Coupled Inductor ....................................................................................... 23 7.3.1 The Toroid Layout .......................................................................................... 23 7.3.2 Inductances.................................................................................................... 23 7.4 The Mag Amp Inductor.......................................................................................... 24 7.4.1 Core Specification .......................................................................................... 24 7.4.2 Winding Instruction......................................................................................... 24 8 PIXls Design Spreadsheet ........................................................................................ 25 9 Test Results .............................................................................................................. 30 10 Performance Data..................................................................................................... 31 10.1 Efficiency and Regulation .................................................................................. 31 10.2 Power Limit vs. Input Line.................................................................................. 32 11 Waveforms................................................................................................................ 33 11.1 Drain Switching Waveforms............................................................................... 34 11.2 Output Ripple Measurements ............................................................................ 36 12 Conducted EMI ......................................................................................................... 37 13 Revision History ........................................................................................................ 38
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Page 2 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
Important Note: Although the EP-12 is designed to satisfy safety isolation requirements, this engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board.
Page 3 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
1
Introduction
The following engineering report gives the detailed description and test data for a TOP247 forward converter designed for 145 W PC main applications and a TNY266 flyback for PC standby. The requirements listed below are typical of a PC power supply.
Figure 1 - EP-12 Populated Circuit Board.
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Page 4 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
2
2.1
Supply Requirements
Power Supply Specification
Description Symbol VIN fLINE Min 90 47 Typ 115 50/60 0.91 4.2 3.30 Max 132 63 1 5 3.43 50 12 5.25 50 15 12.84 120 3 5.25 50 2.0 175 12.5 Units VAC Hz W W V mV A V mV A V mV A V mV A W W %
Measured at PO_main =150 W
Comment
Doubler Input 0.5 W Output From Standby 2.5 W output From Standby 4% 20 MHz Bandwidth 5% 20 MHz Bandwidth 7% 20 MHz Bandwidth 5 A, 15 s Surge 5% 20 MHz Bandwidth 2.5 A, 15 s Surge
Input Voltage Frequency Standby Input Power (115 VAC) Blue Angel Input Power (240 VAC) Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Output Voltage 2 Output Ripple Voltage 2 Output Current 2 Output Voltage 3 Output Ripple Voltage 3 Output Current 3 Output Voltage 4 (standby) Output Ripple Voltage 4 Output Current 4 Total Output Power Continuous Output Power (main) Continuous Output Power (s/b) Efficiency Main Converter Environmental Conducted EMI Safety Surge Surge Ambient Temperature
VOUT1 VRIPPLE1 IOUT1 VOUT2 VRIPPLE2 IOUT2 VOUT3 VRIPPLE3 IOUT3 VOUT4 VRIPPLE4 IOUT4 PO_main PO_s/b main
3.17 0.5 4.75 0.4 11.16 0.05 4.75 0
5.00
12.0
5.00
150 10 65 71
Meets CISPR22B / EN55022B Designed to Meet IEC950, UL1950 Class II 1.2/50 s Surge, IEC 1000-4-5, 12 Series Impedance, Differential and Common Mode 100 kHz Ring Wave, 500 A Short Circuit Current, Differential and Common Mode Free Convection, Sea Level
4 4 TAMB 0 50
kV kV
o
C
Page 5 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
2.2
Conditions for Cross Regulation Test
Load 1 2 3 4 5 6 7 8 +5 V 11 A 15 A 2A 0.4 A 5A 15 A 12 A 0A +3.3 V 12 A 7A 2A 0.5 A 3A 7A 12 A 0A +12 V 3A 3A 3A 0.05 A 1A 3A 5 A (15 s) 0A
2.3
Output Characteristics
a. Rise time: all outputs of the power supply must rise from 10% to 90% of their rated output voltages within 2 ms to 20 ms at nominal line, maximum load. b. Turn-on delay time: 1000 ms maximum at nominal line, full load. c. Hold-up time: 16 ms minimum for all outputs at 110 VAC, 60 Hz, and full load. 2.4 Transient Overshoot
a. +5 V, +12 V and +3.3 V dynamic load transient response. Transient response is measured by switching the output load from 80% to 100% to 80% of its maximum load, other outputs are under maximum load with an input voltage from 90 VRMS to 132 VRMS and at a frequency of 100 Hz and 50% duty cycle, step load change is 0.5 A/s. The peak transient amplitude is less than or equal to +5% / -5% of +5 V, +12 V, +3.3 V output. The recovery time is less than 5 ms. b. Overshoot: +5 V: 5.5 V maximum +3.3 V: 3.63 V maximum 2.5 Short Circuit Protection
The main supply shall latch off from a shorted output condition. The latch is reset through toggling remote ON/OFF.
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Page 6 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
3
Schematics
Figure 2 - EP-12 Main Forward Converter Primary Side.
Page 7 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
Figure 3 - EP-12 Main Forward Converter Secondary Side.
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Page 8 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
Figure 4 - EP-12 Standby Flyback Converter.
Figure 5 - EP-12 Remote ON / OFF Interface.
Page 9 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
4 Circuit Description
With line feed forward, duty factor reduction, programmable primary current limit, linesense for input UV and OV, and soft-start function for smooth start-up, the TOPSwitch-GX family has all the needed functions to operate in an off-line, singleended forward converter configuration. Also the TOPSwitch-GX family has a sufficient power capability to bring PC main applications easily within its reach. In the present design the LINE-SENSE pin (L pin, please refer to TOPSwitch-GX data sheet) senses the rectified DC input voltage through the combination of R3, R5, and R6 and inhibits the supply from switching until the minimum voltage of 80 VAC (doubled mains) or 160 VAC is reached. Upon reaching this voltage and activation of switching, current sourced from R8 will immediately establish a maximum duty factor limit by injecting the appropriate amount of current into the LINE-SENSE pin (adjusting maximum duty factor, please refer to TOPSwitch-GX data sheet). The input from R8 is a quasiintegrated, DC-rectified forward voltage sourced from the bias winding and will restrict the duty factor to a greater degree as the line voltage is increased. This is a very significant function to ensure that the transformer will not saturate, even in extreme transient load conditions. A TOP247 was selected for this 145 W application and its primary current limit was adjusted to limit at approximately 2.5 A by R12 when U3 is on. This allows approximately 170 W of peak output power. Lowering the input voltage will cause the converter to shut off by means of the undervoltage lockout circuit around Q1. When input voltage is low enough to bias on Q1, the collector of Q1 will pull up the X pin of the TOP247 via R39 and shut off the main converter. This design uses a Zener primary clamp (D3, D4, D5) with a capacitor (C4) in parallel that is coupled to the drain of the TOPSwitch-GX through a diode (D1). This is a very efficient snubber as it allows the maximum flyback voltage to develop during the off time which returns a significant amount of energy back to the transformer during the reverse time recovery of the diode D1. The total dissipation of the primary snubber clamp circuit was measured to be only 0.8 W at maximum load. It is necessary to use voltage mode control in the regulation loop when using TOPSwitch-GX. As the data will show, the transient response is very good and there appears to be no difficulty in compensating the voltage mode control loop for optimal performance. The remote ON/OFF function is implemented by using a very simple circuit around Q3. When the ON line (green wire in output cable) is grounded to secondary return, Q3 is turned on and drives the LED of U3 on, which will ground R12 on the primary side and
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Page 10 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
enable the TOP247 via its X pin. If the output comes up into regulation before C19 completely discharges, Q3 is sustained on through R28 and the converter remains running. Upon loss of regulation, Q3 will turn off and the converter will shut off. Toggling the ON/OFF input will allow the converter to retry operation. When the ON line is open, it is internally pulled up to the +5 V standby and the main converter remains in the inhibit state. The +5 V standby is always operating provided there is sufficient AC input to the supply. By connecting the ON line to output return, the main supply will turn on, provided there is sufficient input voltage and there is no fault condition. If there is a fault then the supply will latch off. A retry is accomplished by simply toggling the ON line. Note: If the remote ON line is connected to output return (main power enabled) while turning on AC into the supply, the main converter will automatically turn on. However, if AC is brought up too slowly (i.e. adjusting a variac), the supply will not turn on and the ON line will have to be toggled to turn on the supply. The output interconnect board provided has the ON line already connected to an ON/OFF switch for manual ON/OFF control via the ON line.
Page 11 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
5
PCB Layout
Figure 6 - EP-12 Assembly Diagram.
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Page 12 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
Figure 7 - EP-12 Top View.
Page 13 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
6
6.1
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Bill Of Materials
Electrical Bill of Materials
Qty 1 1 1 1 2 2 2 1 1 2 7 2 1 1 1 2 2 1 1 1 1 2 1 1 2 2 2 1 2 1 3 2 1 2 1 1 1 9 Reference Part Number Manufacturer BR1 KBL06 Gen. Semi. CX1 ECQ-U2A104ML Panasonic CX2 ECQ-U2A334MG Panasonic CY1 440LQ47 Vishay/Sprague CY4, CY3 ECK-ATS222ME Vishay/Sprague C3, C2 200AXW330MK1835 Rubycon C102, C4 200 pF, 1000 V, Y5P, 10% Xicon C5 ECA-2AHG010 Panasonic C19 ECA-1CHG220 Panasonic C6 ECA-1CHG470 Panasonic C7, C13, C14, ECU-S1H104MEA Panasonic C18, C103, C107 C8, C23 ECU-S1H333MEA Panasonic C9 K473K15X7RF5TL2 BC Components C10 ECU-S1H102JCB Panasonic C11 EEU-FC1C102 Panasonic C15, C12 EEU-FC0J222 Panasonic C16, C17 ECA-1AFQ122 Panasonic C20 ECU-S1H331JCA Panasonic C21 ECA-2AHG2R2 Panasonic C22 ECU-SIH101JCA Panasonic C101 10,000 pF, 500 V, Y5P, 10% Xicon C104, C105 ECA-1AFQ102L Panasonic C106 ECA-1AH6471 Panasonic D1 1N5407 Diodes Inc. D4, D5 BZY97C-180 Philips D6, D18 BAV20 Diodes Inc. D7, D9 MBR2045CT Int. Rect. D8 MBR3045WT Int. Rect. D11, D10 UF4002-1 Fagor D12 1N5228B-D7 Gen. Semi. D13, D104, D105 1N4148-T Diodes Inc. D14, D19 Philips D101 1N4006G-T Diodes Inc. D3, D102 BZY97-C200 Philips D103 1N5822 Gen Semi F1 3721400041 Wickmann JP9 Sleeving Sleeving (Alpha TFT250 #18) Alpha JP2, JP3, JP4, (cut from wire roll) Belden JP5, JP6, JP7 8019 000 #18 JP8, JP9, JP10, JP11 L1 coupled choke 13 H/15 A DT Magnetics L5, L2 SPE-119-0 Prem Mag L3 DT Magnetics L4 5702 J.W. Miller L7 ELF-18D650C Panasonic L101 R622LY-100K TOKO Q1 TO-92 Transistor/PNP Description KBL06 0.1 F, 250 VAC 0.33 F, 250 VAC 47 pF, 1 kV (Safety) 2.2 nF(Safety) 330 F, 200 V 2.2 nF, 1 kV 1 F, 100 V 22 F, 16 V 47 F, 16 V 0.1 F, 50 V 0.033 F 0.047 F, 50 V 0.001 F, 50 V 1000 F, 16 V 2200 F, 6.3 V 1200 F, 10 V 330 pF, 50 V 2.2 F, 100 V 100 pF, 50 V 0.01 F, 500 V 1000 F, 10 V 470 F, 10 V 1N5407 BZY97C-180 BAV20 MBR2045 MBR3045 UF4002 1N5228 1N4148 BZX79-C B4V3 1N4006 BZY97-C200 1N5822 4A Insulation/Sleeving JUMPER 13 H 0.5 H Mag amp 20 H, 12 A 8.2 mH 10 H, 2 A 2N3906
39 40 41 42 43 44 45
1 2 1 1 1 1 1
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Page 14 of 40
01-Feb-05
Item 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 Qty 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 2 2 1
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
Reference Q2 Q3, Q7 Q4 Q6 RT1 RV1 R1, R2 R3 R4 R6 R7 R8 R5 R9 R10 R39 R12 R13 R14 R15 R16, R23, R35 R31, R17 R18 R19 R20 R21 R22 R24 R25 R26 R11, R27 R28, R33 R29, R30 R32 R34 R36 R37 R101 R103, R102 R104 R105, R38 R106 T1 T101 U1 U2 U102, U3 U6, U5 U101 Part Number TO-220 Power Transistor/PNP TO-92 Transistor/NPN TO-92 transistor/PNP 300 V TO-92 transistor/NPN 300 V RL3004-6.56-59-S7 ERZ-V14D431 CFR-25JB-330k CFR-25JB-2M2 CFR-25JB-2M2 CFR-25JB-2M2 CFR-25JB-560K MFR-25FBF-130K CFR-25JB-180K CFR-25JB-47R CFR-50JB-560K CFR-25JB-3K3 CFR-25JB-7K5 CFR-25JB-10R CFR-25JB-75K CFR-25JB-1K8 CFR-25JB-1K0 CFR-25JB-15K CFR-25JB-4K64 CFR-25JB-4K12 CFR-25JB-150K CFR-25JB-270R CFR-25JB-3R0 CFR-25JB-3K48 CFR-25JB-2K2 CFR-25JB-10K CFR-25JB-390R CFR-25JB-4K7 CFR-25JB-100K RSF100JB-1R0 CFR-25JB-27K CFR-25JB-33R MFR-25FBF-43K2 CFR-25JB-10K CFR-25JB-51R CFR-25JB-4M0 CFR-25JB-430R CFR-25JB-5k1 CFR-25JB-27K EER-28L EE-16 TOP247Y1 SFH615A-2 LTV817 TL431 TNY266P Manufacturer Description TIP32C 2N3904 MPSA42 MPSA92 10 275 V, 14 mm 330 k 2.2 M 2.2 M 2.2 M 560 k 130 k, 1% 180 k 47 560 k, 1/2 W 3.3 k 7.5 k 10 75 k 1.8 k 1 k 15 k 4.64 k, 1% 4.12 k, 1% 150 k, 1% 270 3 3.48 k, 1% 2.7 k 10 k 390 4.7 k 100 k 1 , 1 W 27 k 33 43.2 k, 1% 10 k 51 1 M, 1% 430 5.1 k 27 k PC Main Transformer PC Standby Transformer TOP247Y1 SFH615A-2 LTV817 TL431 TNY266P
Keystone Panasonic Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo DT Magnetics DT Magnetics Power Integrations Sharp
Power Integrations
Page 15 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
6.2
Hardware Bill of Materials
Description PCB, Assembly Main Top & Bottom Enclosure, Fan, Fan Screws (2 ea), AC Input Conn, Voltage Selection Switch Conn, Spade 16-22 AWG, #10 PIDG Cap, 470 pF, 20% 250 V, Ceramic Y2/X1 Wire, Grn/Yel, 18 AWG UL1015, Pretinned Wire, Wht, 18 AWG UL1015, Pretinned Wire, Blk, 18 AWG UL1015, Pretinned Wire, Wht, 22 AWG UL1015, Pretinned Tie Wrap, 4", Nylon Screw, M3 X 5 mm Screw, #6 X 1/4 Pan Head, Type B, Self Tap, Zinc Pltd Insulator, Fishpaper Rev D P/N DAK-12 N/A Manufacturer Power Integrations N/A
Item Qty Reference 1 1 ea PCB, Main 2 1 kit Enclosure/Hardware
3 4 5 6 7 8 9 10 11
1 ea Conn, Spade 2 ea Cap 2.5" 4" 4" 12" N/A N/A N/A N/A
31887 ECK-ATS471MB
AMP Panasonic Any Any
1015-18/1-0
Any Any
4 ea N/A 2 ea N/A 7 ea N/A
PLT1M 6N25PPBZZ
PANDUIT Any Any
12
1 ea N/A
6.3
Output Cable Bill of Materials
Description Recp, 2 X 10 4.2 mm Mini-Fit Jr Terminal, Crimp, Fem AWG 18-24, Tin Wire, Blk, 18 AWG, UL 1015 Wire, Red, 18 AWG, UL 1015 Wire, Org, 18 AWG, UL 1015 Wire, Yel, 18 AWG, UL 1015 Wire, Grn, 22 AWG, UL 1015 Wire, Vio, 22 AWG, UL 1015 Conn, Wire Pin Term 10-12 AWG Tool, Hand Crimper Mini-Fit Jr. 18-24 AWG Tool, Extraction Mini-Fit Jr Tool, Hand Crimper Wire Pin Term (Molex 19211-0001) P/N 39-01-2205 (94V-0) 39-00-0039 Manufacturer MOLEX MOLEX Any Any Any Any Any Any MOLEX MOLEX MOLEX MOLEX
Item Qty Reference 1 1 ea P2 2 3 4 5 6 7 8 9 10 11 12 17 ea N/A 70" 30" 30" 10" 10" 10" 4 ea N/A N/A N/A N/A N/A N/A Conn A, B, C, F Tool Tool Tool
19211-0001 11-01-0197 11-03-0044 19285-0063
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Page 16 of 40
01-Feb-05 6.4
Item 1 2 3 4 5 6 7 8
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
Heatsinks Bill of Materials
Qty 1 1 4 1 1 4 4 1 Part Reference Description Fab, H.S. Primary, EP-12 Rev. D Fab, H.S. Secondary, EP-12 Rev. C Scr, Phil Pan, M3 X 8, Stl, Znc Scr, Phil Pan, M3 X 10, Stl, Znc Wshr, Split Lock, M3 Wshr, Shldr, #4 [M2, 5] Sil-Pad 600, Heatsink, TO-220 Sil-Pad TO-3P Heatsink, TO-247 P/N Manufacturer
U1, D7, D9, Q2 D8 U1 U1, D7, D9, Q2 U1, D7, D9, Q2 D8
3049 BER102 BER109
Olander Co. Olander Co. Olander Co. Keystone Berquist Berquist
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
7
7.1
Transformer Specification
145 W Forward Transformer
Figure 8 - EP-12 145 W Forward Transformer.
7.1.1 Electrical Specifications
Electrical strength Primary Inductance Resonant Frequency Primary leakage inductance 60 Hz, 1 min, from Pins 1-7 to Pins 10-14 All windings open All windings open Pins 6-14 shorted 3000 VAC 4.5 mH or Higher 0.2 MHz minimum 8 H maximum
7.1.2 Materials
Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description Core: PC40 EER28L Bobbin: BEER28L-1114CPH Magnet Wire: #28 AWG Heavy Nyleze Magnet Wire: #30 AWG Heavy Nyleze Magnet Wire: #20 AWG Heavy Nyleze Copper ribbon .670 x .008 Tape: 3M 1298 Polyester Film (white) 21.8 mm wide by 2.2 mils thick Tape: 3M 1298 Polyester Film (white) 15.8 mm wide by 2.2 mils thick Tape: 3M 44 Margin tape (cream) 3.0 mm wide by 5.5 mils thick
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Page 18 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
7.1.3 Transformer Build Diagram
Figure 9 - EP-12 145 W Forward Transformer Build Diagram.
7.1.4 Transformer Construction
Margin Taping Primary Winding Basic Insulation Margin Taping Bias Winding Reinforce Insulation Copper Foil Winding (5 V) Reinforce Insulation Margin Taping 12 V Winding Outer Insulation Use item [9] for the right and left margins. Start at pin 5. Wind 45 turns of item [3] from left to right. Wind uniformly in a single layer. End at pin 1. 1 Layer of tape [8] for basic insulation. Use item [9] for the right and left margins. Start at pin 3. Wind trifilar 6 turns of item [4] from left to right. Wind uniformly in a single layer, across entire width of bobbin. Finish on pin 7. 3 Layers of tape [7] for insulation. Prepare copper ribbon [6] as shown in Figure 10. Match pin A of the foil to pin 11 or 12 of the bobbin. Wind 3 turns of item [6]. Finish by matching pin B of the foil to pins 8 and 9 of the bobbin. 3 Layers of tape [7] for insulation. Use item [9] for the right and left margins. Start at pin 13. Wind 4 turns of item [5] from left to right. Wires are populated in middle of bobbin. Finish at pin 14. 3 Layers of tape [7] for insulation.
Page 19 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
Figure 10 - +5 V Foil (measurements are in mm).
Figure 11 - +5 V Foil and Tape.
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Page 20 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
7.2
10 W PC Standby Transformer
Figure 12 - EP-12 10 W Standby Transformer.
7.2.1 Electrical Specifications
Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 1 min, 60 Hz, from pins 1-4 to pins 5-10 All windings open All windings open Pins 6-10 shorted 3000 VAC 2.3 mH 800 kHz minimum 130 H maximum
7.2.2 Materials
Item [1] [2] [3] [4] [5] [6] [7] Description Core: EE16 Bobbin: BE-16 Magnet Wire: #35 AWG Heavy Nyleze Triple Insulated Wire: #26 AWG Magnet wire #30 AWG heavy Nyleze Tape: 3M 1298 Polyester Film (white) 9.0 mm wide by 2.2 mils thick Varnish
Page 21 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
7.2.3 Transformer Build Diagram
Figure 13 - EP-12 10 W Standby Transformer Build Diagram.
7.2.4 Transformer Construction
Start at Pin 7. Wind 158 turns of item [3] from left to right, then from right to left until done. It takes about 3 1/4 layers. Apply 1 layer of tape, item [5] between each winding layer for basic insulation. Finish the wiring on Pin 5. 1 Layer of tape [6] for insulation. Start at pin 9. Wind 17 turns of item [5] from left to right. Finish on pin 10. 1 Layer of tape [6] for insulation. Start at Pin 2. Wind 7 bifilar turns of item [4] from left to right. Wind uniformly, in a single layer, across entire width of bobbin. Finish on Pin 1. 3 Layer of tape [6] for insulation. Assemble and secure core halves. Impregnate uniformly [7].
Primary Layer Insulation Bias Winding Insulation Secondary Winding Outer Insulation Final Assembly
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Page 22 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
7.3
Output Coupled Inductor
7.3.1 The Toroid Layout
Figure 14 - The Side View. (Measurements are in inches).
Figure 15 - Bottom Plate Viewed from Top. (Measurements are in inches).
Figure 16 - EP-12 Inductor.
7.3.2 Inductances
Pin # 6-1 5-2 3-4 AWG # 18 18 18 Color Red Red Natural # of Turns 12 12 16 Inductance (H) 13 20% 13 20% 23 20%
Note: 1 All dimensions are 0.02" 2 Core = T 106 - 26
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
7.4
The Mag Amp Inductor
7.4.1 Core Specification
Figure 17 - EP-12 Core Measurements.
Figure 18 - EP-12 Core.
Core Number MP1305P-4AS
OD 14.4 mm
ID 7.9 mm
HT 6.6 mm
7.4.2 Winding Instruction Use number 18 AWG wire (heavy gauge Nyleze wire) to wind 7 turns around the core as shown in Figure 18. Leave the wire legs about 1 long.
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Page 24 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
8
PIXls Design Spreadsheet
INPUT INFO OUTPUT UNIT ACDC_TOPGXFwd_061802_r103.xls: TOPSwitch-GX Forward Transformer Design Spreadsheet EP12 PC Main power supply 5 12 3.3 12 12 4 Volts Amps Volts Amps Volts Amps Volts Amps 147.6 Watts Main output voltage Main output current Magamp output voltage Magamp output current Auxiliary output voltage Auxiliary output current Independent output voltage Independent output current Total output power
ACDC_TOPGXForward_Rev_1.03_061 802 Copyright Power Integrations Inc. 2002 OUTPUT VOLTAGE AND CURRENT VMAIN IMAIN VMAINMA IMAINMA VAUX1 IAUX1 VIND1 IND1 PO ENTER APPLICATION VARIABLES VACMIN VACMAX VMIN VMAX CIN fL tc th EFF VHOLDUP VDROPOUT DMAX GOAL VDSOP KDI REF AUX1
90 132
AC volts AC volts 188 Volts 373 Volts
Minimum AC input voltage. Input voltage doubler circuit is assumed. Maximum AC input voltage. Input voltage doubler circuit is assumed. Minimum DC Bus voltage at low line input Maximum DC Bus voltage at high line input Equivalent bulk input capacitance. Input voltage doubler circuit is assumed. Input AC line frequency Estimate input bridge diode conduction time Minimum required hold-up time from VDROPOUT to VHOLDUP Efficiency estimate to determine minimum DC bus voltage DC Bus voltage at start of hold-up time (default VMIN) DC Bus Voltage at end of hold-up time Maximum duty cycle at DC dropout voltage Maximum operating drain voltage Maximum output current ripple factor at maximum DC Bus voltage Enter one ("1") for DC stacked, zero ("0") Independent winding
165 50 3.0 16.0 0.75
uFarads Hz mSeconds mSeconds
188 Volts 132 0.7 132 Volts 0.70 580 Volts 0.15 1 DC Stack
ENTER TOPSWITCH VARIABLES TOPSwitch Chosen Device ILIMIT fS KI RX ILIMITEXT VDS top247 TOP247 3.348 124000 0.81 7.78 kOhm 2.712 Amps 8.1 Volts 3.852 132000 Power Out Universal Amps Hertz Doubled 115V/230V 165 W From TOPSwitch-GX datasheet From TOPSwitch-GX+H76 datasheet limit reduction (KI=1.0 for default ILIMIT, KI <1.0 for lower ILIMIT) Maximum current limit resistance to ensure KI >= 0.81 setting External current limit TOPSwitch-GX average on-state Drain to Source Voltage
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
DIODE Vf SELECTION VDMAIN VDMAINMA VDAUX1 VDIND1 VDB BRIDGE RECTIFIER DIODE SELECTION VPIVAC IDAVBR TRANSFORMER CORE SELECTION Core Type Core Bobbin AE LE AL BW LG MAX R FACTOR M L NMAIN TRANSFORMER DESIGN PARAMETERS NP NB NAUX1 VAUX1 ACTUAL NIND1 VIND1 ACTUAL 9% 3.0 0.80 3 eer28l EER28L EER28L_ BC P/N: P/N: 0.814 cm^2 7.55 cm 2520 nH/T^2 21.8 mm 0.02 mm 9% % mm PC40EER28L-Z BEER-28L-112CPH Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Maximum actual gap when zero gap specified Percentage of total PS losses lost in transformer windings; default 10% Transformer margin Transformer primary layers Main rounded turns 467 Volts 0.773 Amps Maximum voltage across Bridge rectifier diode Average Bridge Rectifier Current 0.5 Volts 0.5 Volts 0.7 Volts 0 Volts 0.7 Volts Main output rectifiers forward voltage drop (Schottky) Magamp output rectifiers forward voltage drop (Schottky) Auxiliary output rectifiers forward voltage drop (Ultrafast) Independent output rectifiers forward voltage drop (Schottky) Bias output rectifier conduction drop
45
45 6 4 11.63 Volts 0 0.00 Volts
Primary rounded turns Bias turns to maintain 8V minimum input voltage, light load Auxiliary rounded turns (DC stacked on Main winding) Approx. Aux output voltage with NASUX1 = 4 Turns and DC stack Independent rounded turns (separate winding) Approximate independent output voltage with NIND1 = 0 turns Maximum operating flux density at minimum switching frequency Maximum peak flux density at minimum switching frequency Minimum primary magnetizing inductance (assumes LGMAX=20um) Peak magnetizing current at minimum input voltage Primary wire outer diameter Primary Wire Gauge (rounded to maximum AWG value)
BM BP LP MIN IMAG OD_P AWG_P
1816 Gauss 2884 Gauss 3.419 mHenries 0.189 Amps 0.33 mm 28 AWG
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01-Feb-05
CURRENT WAVESHAPE PARAMETERS IP IPRMS
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
2.451 Amps 1.460 Amps
Maximum peak primary current at maximum DC Bus voltage Maximum primary RMS current at minimum DC Bus voltage
INDUCTOR OUTPUT PARAMETERS LMAIN WLMAIN KDIMAIN LMAINMA WLMAINMA KDIMAINMA LIND1 WLIND1 KDIIND1 SECONDARY OUTPUT PARAMETERS ISMAINRMSLL ISAUX1RMSLL ISIND1RMSDLL 15.61 Amps 2.42 Amps 0.00 Amps Maximum transformer secondary RMS current (DC Stack) Maximum transformer secondary RMS current (DC Stack) Maximum transformer secondary RMS current (DC Stack) Maximum average current, Main rectifier (single device rating) Maximum average current, Magamp rectifier (single device rating) Maximum average current, Auxiliary rectifier (single device rating) Maximum average current, Independent rectifier (single device rating) Maximum capacitor Maximum capacitor Maximum capacitor Maximum capacitor RMS current, Main output RMS current, Magamp output RMS current, Auxiliary output RMS current, Independent output 10.0 uHenries 2286 uJoules 0.150 12.3 uHenries 888 uJoules 0.150 0.0 uHenries 0.0 uJoules 0.000 Main / Auxiliary coupled output inductance (referred to Main winding) Main / Auxiliary coupled output inductor fullload stored energy Current ripple factor for Magamp output Magamp output inductance Magamp output inductor full-load stored energy Current ripple factor for Magamp output Independent output inductance Independent output inductor full-load stored energy Current ripple factor for independent output
IDAVMAIN IDAVMAINMA IDAVAUX1 IDAVIND1
12.3 Amps 9.3 Amps 3.1 Amps 0.0 Amps
IRMSMAIN IRMSMAINMA IRMSAUX1 IRMSIND1
0.52 Amps 0.52 Amps 0.17 Amps 0.00 Amps
DIODE PIV VPIVMAIN VPIVMAINMA VPIVAUX1 VPIVIND1 VPIVB 29.5 Volts 29.5 Volts 34.9 Volts 0.0 Volts 102.1 Volts
No derating Main output rectifiers peak-inverse voltage Magamp output rectifiers peak-inverse voltage Auxiliary output rectifiers peak-inverse voltage Independent output rectifiers peak-inverse voltage Bias output rectifier peak-inverse voltage Optocoupler
VCEO OPTO
49.8 Volts
Maximum optocoupler collector-emitter
Page 27 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
voltage UNDER-VOLTAGE LOCKOUT CIRCUIT PARAMETERS VACUVL VACUV VACUVX RUVA RUVB RUVC 68 AC volts 78 AC volts 68 2.23 MOhm 523.73 kOhm 75.91 kOhm Resistor RUVA value Resistor RUVB value Resistor RUVC value
01-Feb-05
AC undervoltage lockout voltage; On-Off transition AC undervoltage lockout voltage; Off-On transition
VACUVL ACTUAL VACUVX ACTUAL
67.50 AC volts 70.36 AC volts
Actual AC undervoltage lockout voltage; OnOff transition Actual AC undervoltage lockout voltage; OffOn transition
DUTY CYCLE LIMIT CIRCUIT PARAMETERS VZ VOV 6.80 Volts 380 Volts Zener voltage used within DLIM circuit Approximate frequency reduction voltage (determines CVS value) Resistor RA value Resistor RB value Resistor RC value Resistor RD value Capacitor CVS value
RA RB RC RD CVS DUTY CYCLE PARAMETERS (see graph) DMAX ACTUAL DMAX RESET DXDO MIN DXDO MAX Caution
2.20 MOhm 2.20 MOhm 40.26 kOhm 126.70 kOhm 92.98 pF
Dropout Duty-Cycle Parameters 0.69 0.79 0.70 0.79 Operating Duty cycle at DC Bus dropout voltage Transformer Reset Minimum duty cycle at DC Bus dropout voltage Device Min Duty cycle limit at DC Bus dropout voltage !!! >DMASRESET from VMIN to VDROPOUT. NOT hazardous Duty cycle at minimum DC Bus voltage Duty cycle minimum limit at minimum DC Bus voltage Duty cycle maximum limit at minimum DC Bus voltage Minimum duty cycle to reset transformer at low line High Line Duty-Cycle Parameters
DLL ACTUAL DXLL MIN DXLL MAX DLL RESET
0.47 0.55 0.67 0.69
DHL ACTUAL DXHL MIN DXHL MAX DHL RESET
0.23 0.24 0.35 0.36
Duty cycle at minimum DC Bus voltage Duty cycle minimum limit at maximum DC Bus voltage Duty cycle maximum limit at maximum DC Bus voltage Minimum duty cycle to reset transformer at high line
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01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
DX_MAX D_RESET
D_ACTUAL
DX_MIN
Figure 19 - PIXls Duty Cycle Reduction Parameters Chart.
Page 29 of 40
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
9
Test Results
Thermal and Dissipation Data TOP247 dissipation at 90 VAC and 5 V at 15 A, 3.3 V at 7 A, 12 V at 4 A (approximately 140 W) was measured 5.4 W. The unit was enclosed in a standard ATX enclosure. The ambient external temperature around the enclosure was 25 C and the internal ambient in the enclosure in the box near TOP247 heatsink was measured 37 C. The TOP247 source tab temperature for above conditions was measured 53 C.
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01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
10 Performance Data
10.1 Efficiency and Regulation
Output Current Load Input VAC +5 V (A) 1 2 3 4 5 6 7 8 9 10 11 12 132 132 132 132 90 90 90 90 115 230 115 115 0.4 15 0.0168 1.9690 0.5 12 0.4 0.4 0.4 0.4 15 15 15 15 15 +12 V (A) 0.05 0.05 3 3 0.05 0.05 3 3 3 +3.3 V +5 VSB (A) 0.5 12 0.5 12 0.5 12 0.5 12 12 (A) 0 2 2 0 2 0 0 2 2 0.5 2 2 5.1 4.99 12.1 12.03 3.33 3.2 +5 V (V) 5.09 5.07 5.11 5.1 5 5 5.02 4.99 4.99 Output Voltage +12 V (V) 12.02 11.92 11.6 11.54 12.41 12.45 11.95 11.92 11.93 +3.3 V +5 VSB (V) 3.31 3.21 3.29 3.23 3.28 3.2 3.28 3.2 3.21 (V) 5.05 4.89 4.84 5.1 4.8 5.07 5.13 4.86 4.83 4.87 4.87 4.87 (W) 10 72 62 103 114 154 146 223 217 3.9 20 198 43% 71% 77% 72% 76% 74% 77% 71% 73% 64% 67% 74% Pin Efficiency
Note: 12 V load table does not include the 100 mA internal load, which is equivalent to fan loading.
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
10.2 Power Limit vs. Input Line
Total Output Power (Watts) at Threshold of Over Power Shutdown 179 178 177 176 175 174 173 172 171 90 100 110 120 130 140 AC Input (Volts)
Figure 20 - Power Limit vs. Input Line.
Standby Input Power The input power with standby loaded to 0.5 W and main supply off at 115 VAC input is 0.91 W. Note: when measuring for less than 1 W input power spec and output interconnect board is used, the yellow standby on LED on the board dissipates 0.07 W. This should be considered part of the output loading. Blue Angel 240 VAC input, main converter inhibited, +5 V standby loaded to 2.5 A. Input power is 4.2 W.
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Total Ouptut Power (Watts)
Page 32 of 40
01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
11 Waveforms
0.5 A/div
+ 5 V output
3.3 V Output
Figure 21 - Primary Drain Current at Start-up, Activated from Remote ON/OFF with 120 VAC Input.
Figure 22 - +5 V and 3.3 V Rise at Turn-on from Remote ON/OFF , 120 VAC Input, 5 V out at 12 A, 3.3 V at 12 A, 0 A on +12 V.
5 V Standby
5 V Standby
5 V Main
5 V Main
Figure 23 - 5 V Main and 5 V Standby Start-up (120 VAC). Max Load on all Outputs.
Figure 24 - 5 V and 5 V Standby Drop out After AC off Max Load on 5 V Standby, Min Load on all Other Outputs.
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
11.1 Drain Switching Waveforms 5 V @ 12 A, 3.3 V @ 12 A, 12 V @ 3 A
Figure 25 - Drain to Source Voltage of TOP247 at 220 VAC.
Figure 26 - Drain to Source Voltage of TOP247 at 165 VAC.
Figure 27 - Drain to Source Voltage of TOP247 at 270 VAC.
Figure 28 - Drain to Source Voltage of TOP247 at 270 VAC Input 3.3 V Output Shorted at PC Board.
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01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply
5 V Standby
5 V Output
Input Line Current Figure 29
- 110 VAC Applied Line Terminated
with Following Loads: 5 V at 13 A, 3.3 V at 12 A, 12 V at 3.5 A.
Figure 30 - Drain Switching Voltage of TNY266 (PC Standby) 230 VAC Input 5 V Loaded to 1.5 A.
Figure 31 - 5 V Step Load (8 A/15 A) Maximum Continuous Load on Other Outputs.
Figure 32 - 3.3 V Step Load 6 A/12 A.
+ 5 V Standby Output
Step Load 0.3 A to 1.5 A Figure 33 - +5 V Standby Step Load Response.
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
11.2 Output Ripple Measurements Output ripple measured with following load: 12 V @ 3 A, 5 V @ 12 A, 3.3 V @ 12 A, 5 V standby @ 2 A.
Figure 34 - +12 V Output Ripple.
Figure 35 - +5 V Output Ripple.
Figure 36 - +3.3 V Output Ripple.
Figure 37 - +5 V Standby Output Ripple.
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
12 Conducted EMI
Figure 38 - 230 VAC, Neutral Input, Maximum Load on all Outputs.
Figure 39 - 230 VAC Line Input, Maximum Load on all Outputs.
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
13 Revision History
Date 09-Jul-02 30-Aug-02 21-Oct-02 01-Feb-05 Author AO AO AO AO Revision 1.0 1.1 1.2 1.3 Description & Changes First release Corrected schematic on page 8 and caption on Figure 22 Corrected Figure 11 Corrected 7.2.1 Primary Inductance on page 21 and added missing Part Numbers on page 15
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01-Feb-05
EPR-12 - PC Forward Converter with Standby Flyback Power Supply Notes
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EPR-12 - PC Forward Converter with Standby Flyback Power Supply
01-Feb-05
For the latest updates, visit our website: www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch and EcoSmart are registered trademarks of Power Integrations. PI Expert and PI FACTS are trademarks of Power Integrations. (c) Copyright 2005 Power Integrations.
Power Integrations Worldwide Sales Support Locations
WORLD HEADQUARTERS 5245 Hellyer Avenue, San Jose, CA 95138, USA Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: usasales@powerint.com GERMANY Rueckertstrasse 3, D-80336, Munich, Germany Phone: +49-895-527-3910 Fax: +49-895-527-3920 e-mail: eurosales@powerint.com JAPAN Keihin-Tatemono 1st Bldg. 12-20 Shin-Yokohama, 2-Chome, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033, Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com KOREA RM 602, 6FL Korea City Air Terminal B/D, 159-6, Samsung-Dong, Kangnam-Gu, Seoul, Korea Phone: +82-2-2016-6610 Fax: +82-2-2016-6630 e-mail: koreasales@powerint.com SINGAPORE 51 Newton Road, #15-08/10 Goldhill Plaza, Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com TAIWAN 5F-1, No. 316, Nei Hu Rd., Sec. 1 Nei Hu Dist. Taipei, Taiwan 114, R.O.C. Phone: +886-2-2659-4570 Fax: +886-2-2659-4550 e-mail: taiwansales@powerint.com
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