1 Schematic 2 Bill of Materials

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1 Schematic 2 Bill of Materials
1 Schematic
Figure 1 – Schematic.
2 Bill of Materials
Item
Quantity Ref.Des
Numbe
r
1
1 BR1
2
1 C1
Description
Mfg Part
Number
Mfg
800 V, 1 A, Bridge Rectifier, SMD, DFS
100 nF, 275VAC, Film, X2
DF08S
LE104-M
UVC2G150M
PD
KMG401ELL3
30MK20S
EMK316BJ22
6ML-T
C1206C102K
BRACTU
C2012X5R1E
105K
CD90B2GA331KY
NS
C2012X7R1E
225M
C1608C0G2A
102J
Diodes Inc
OKAYA ELECT
IND CO. LTD.
Nichicon
3
1 C2
15 uF, 400 V, Electrolytic, (10 x 16)
4
1 C3
33 uF, 400 V, Electrolytic, (12.5 x 20)
5
1 C4
22 uF, 16 V, Ceramic, X5R, 1206
6
1 C5
1000 pF, 630 V, Ceramic, X7R, 1206
7
1 C6
1 uF, 25 V, Ceramic, X5R, 0805
8
1 C7
330 pF, 250 VAC, Film, X1Y1
9
1 C8
2.2 uF, 25 V, Ceramic, X7R, 0805
10
2 C9
1000 pF, 100 V, Ceramic, NPO, 0603
Nippon ChemiCon
Taiyo Yuden
Kemet
TDK
TDK
TDK Corp
TDK Corp
11
1 C10
330 pF 50 V, Ceramic, X7R, 0603
12
2 C11 C12
470 uF, 16 V,Al Organic Polymer, 12
mOhm, (8 x 11.5)
13
1 C14
1 uF, 50 V, Ceramic, X5R, 0805
14
1 D1
15
1 D2
16
1 D3
17
1 D4
18
1 F1
19
20
21
2 FL1 FL2
1 FL3
1 J1
22
23
24
2 J2 J3
1 L1
1 L2
25
1 Q1
26
1 R1
200 V, 1 A, Rectifier, Glass Passivated,
POWERDI123
600 V, 1 A, Rectifier, Glass Passivated,
POWERDI123
100 V, 1 A, Schottky, DO-214AC
(SMA)
50 V, 1 A, Rectifier, Glass Passivated,
DO-213AA (MELF)
FUSE, 1.25A 250VAC, Slow, 8.35 mm x
4.0 mm x 7.7 mm
Flying Lead , Hole size 70mils
Flying Lead , Hole size 30mils
OBS, SEE 35-00309-00 for
replacement. AC Input Receptacle
PCB Terminal Hole, 18 AWG
15 mH, Common Mode Choke
90 uH, Common mode choke, 10.55
mm OD X 3.73 mm ID X 4.07 mm Thk
Core
100 V, 27.5 A, N-Channel, PowerPAK
SO-8
360 k, 5%, 1/4 W, Thick Film, 1206
27
1 R2
15 R, 5%, 1/4 W, Thick Film, 1206
28
2 R3 R6
3.9 M, 5%, 1/4 W, Thick Film, 1206
29
1 R4
2.7 k, 5%, 1/10 W, Thick Film, 0603
30
1 R5
15.4 R, 1%, 1/4 W,Thick Film, 1206
31
1 R7
4.3 R, 5%, 1/10 W, Thick Film, 0603
32
1 R8
47 R, 5%, 1/10 W, Thick Film, 0603
33
1 R9
11.5 k, 1%, 1/16 W, Thick Film, 0603
34
1 R10
100 k, 1%, 1/8 W, Thick Film, 0805
CC0603KRX7
R9BB331
Yageo
Nichicon
RNE1C471M
DN1
08055D105K
AT2A
DFLR1200-7
AVX
Corporation
Diodes Inc
DFLR1600-7
Diodes Inc
SS110-TP
Micro
commercial Co.
Diodes Inc
DL4001-13-F
RST 1.25BULK
N/A
N/A
S-01-02A
Bel Fuse Inc
N/A
N/A
SI7456CDPT1-GE3
ERJ8GEYJ364V
ERJ8GEYJ150V
ERJ8GEYJ395V
ERJ3GEYJ272V
ERJ8ENF15R4V
ERJ3GEYJ4R3V
ERJ3GEYJ470V
ERJ3EKF1152V
ERJ6ENF1003V
Vishay/Siliconix
N/A
N/A
Sunfair
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
35
1 R12
0.02 R, 1%, 1/4 W, Thick Film, 0805
36
2 R13 R14
0.12 R, 1%, 1/4 W, Thick Film, 1206
37
38
39
40
1
1
1
1
41
1 VR1
NTC Thermistor, 5 Ohms, 1 A
275 V, 23 J, 7 mm, RADIAL
Bobbin, RM8, Vertical, 12 pins
InnoSwitch-EP, INN2605K, Off-Line
CV/CC Flyback Switcher, ReSOP-16B
DIODE ZENER 4.7V 500MW SOD123
RT1
RV1
T1
U1
RL0805FR7W0R02L
ERJ8RSJR12V
MF72-005D5
V275LA4P
RM8/12/1
INN2605K
MMSZ5230B
-7-F
Yageo
Panasonic
Cantherm
Littlefuse
Schwartzpunkt
Power
Integrations
Diodes, Inc
3 Input Common Mode Choke
3.1 Electrical Diagram
Figure 2 – Inductor Electrical Diagram.
3.2 Electrical Specifications
Inductance
Core Effective Inductance
Primary Leakage Inductance
Pins 1-4 measured at 100 kHz, 0.4 RMS.
Pins 1-4, with 2-3 shorted
15 mH ±10%
4400 nH/N2
90 µH
3.3 Materials List
Item
[1]
Description
Toroid: FERRITE INDUCTR TOROID T14 x 8 x 5.5.
Divider - Fish paper, insulating cotton rag, 0.010” thick,
Cut to size 8 mm x 5.5 mm.
Magnet Wire: #31 AWG Heavy Nyleze.
[2]
3.4 Winding Instructions
•
•
Use 4 ft of item [2], start at pin 1 wind 55 turns end at pin 4
Do the same for another half of Toroid, start at pin 2 and end at pin 3.
4 Output Common Mode Choke
4.1 Electrical Diagram
Figure 3 – Inductor Electrical Diagram.
4.2 Electrical Specifications
Inductance
Primary Leakage
Inductance
Pins 1-4 measured at 100 kHz, 0.4 RMS.
Pins 1-4, with 2-3 shorted.
90 µH ±10%
1 µH
4.3 Materials List
Item
[1]
[2]
[3]
Description
FERRITE CORE TOROID.
Manufacturer Part Number = GL50T 12X6X4-C.
Manufacturer: BIPOLAR ELECTRONIC CO., LTD.
Magnet Wire: #21 AWG.
Triple Insulated wire #21 AWG.
4.4 Winding Instructions
(1) Use item [2] and Item [3] simultaneously, start (left side of the core) at pin 1(item
2, Mark as 1) and at pin 2(item 3, Mark as 2 on the wire) and wind 5 turns end at pin 4
(item 2 Mark as 4), pin 3(item 3, Mark as 3 on the wire)
5 Transformer Specification
5.1 Electrical Diagram
Figure 4 – Transformer Electrical Diagram.
5.2 Electrical Specifications
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage
Inductance
1 second, 60 Hz, from pins 1, 2, 3, 4, 5 to pins
FL1 and FL2.
Pins 2-FL3, all other windings open, measured at
100 kHz, 0.4 VRMS.
Pins 4-5, all other windings open.
Pins 2-FL3, with pins FL1-FL2 shorted, measured
at 100 kHz, 0.4 VRMS.
5.3 Material List
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
Description
Core: RM8-PC47 (PC47RM8Z-12).
Bobbin: RM8-V-12pins(Circle-6/6).
Magnet Wire: #28 AWG.
Magnet Wire: #29 AWG
Triple Insulated Wire: #24 AWG.
Copper Foil.
Tape: 3M 1298 Polyester Film, 2 mil thick, 8.2 mm wide.
Varnish.
3000 VAC
589 µH ±5%
1100 kHz (Min.)
13 µH
5.4 Transformer Build Diagram
WD4: Secondary 5T – 2 x #24AWG_TIW
FL2
FL1
WD3: Bias
4T – 3 x #29AWG
10
11
WD2: Shield
1T Copper Foil
11
WD1: Primary
45T - #28AWG
NC
FL3
2
Figure 5 – Transformer Build Diagram.
5.5 Transformer Construction
WD1
Primary
Insulation
WD2
Bias
Insulation
WD3
Secondary
Insulation
Finish
Start at pin 2, wind 45 turns of #28 AWG item [3] wire in 2 layers. Finished at pin
FL3.
1 layer of tape [7] for insulation.
Start at pin 11, wind 4 trifilar turns of # 29 AWG item [4] from left to right in one
layer, and finish at pin 10.
1 layer of tape [7] for insulation.
Start at FL2, wind 5 bifilar turns of #24 TIW item [5] from left to right. Finish at
FL2.
2 layers of tape [7] for insulation.
1. Gap core at 580 µH.
2. Varnish.

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