Blog 1 : Introduction - Designing with Bourns 2.25-22 W Flyback Transformers

Hello Everyone

This is my 3rd design challenge with e14 (I had withdrawn from the Ist one but I have done new research on it, which can be found in my preprint research papers list and 2-3 more would be added).

Thanks for organizing International contest/International design challenge on 'Flyback Transformer' and choosing me among 10 challengers as an official challenger in 'Experimenting with Flyback Transformers'. I have been involved in the designing of SMPS calculations for more than decade and a half, which are basically elementary for any diploma or graduate.

For this 'Design Challenge',  a new score system is introduced and type of content expected in extra credit blogs is excellently explained here. But I am taking this only as suggestion and won't be strictly following it, in the sense that a particular blog should have particular content only and the rest in other blog.

Table of Contents

1. Unboxing
2. Kit Components
3. Kit Remarks
   1. Flyback Transformer Types Sponsored
   2. Operating Temperature
   3. Moisture Sensitivity Level
   4. Current Range
   5. Hazardous Warning
   6. Standards
   7. Ideal Power, 77DE-10-15M
   8. Compartment Box
4. List of Experiments
5. Experiments Preparation

1. Unboxing

{gallery}My Gallery Title

The packaging was OK and sufficient for the 12 flyback transformers enclosed in box (plastic or Polypropylene) but not good for Ideal power adapter, you can see crack. The Ideal power Adapter should had strong packaging; it was packed in white box as shown, and then there was just outer box, plastic box (with transformers) and brown paper.

All the transformers are correctly placed with numbering from 1 to 12, as in the list here , which was surprising as I was wondering if I have to place them properly in which compartment for experimenting. And if the box is upside down, the transformers do not fall in the adjacent compartment.

2. Kit Components

1. BOURNS PFBR45-ST13150S
2. BOURNS PFBR45-SP13150S
3. BOURNS BA60951CS
4. BOURNS 094929
5. BOURNS 063929 
6. BOURNS 063932
7. BOURNS 093830
8. BOURNS 063934
9. BOURNS 094931
10. BOURNS 094932
11. BOURNS 071923
12. BOURNS 093267
13. DURATOOL D00413 Compartment Box
14. IDEAL POWER, 77DE-10-15M

 I have collected all datasheets together. It can be downloaded from here Datasheets-Experimenting with Flyback Transformers except DURATOOL D00413 Compartment Box datasheeet.

1. BOURNS PFBR45-ST13150S

BOURNS PFBR45-ST13150S is a Gate Drive Transformer and is called by manufacturer BOURNS as Series PLC Transformer because BOURNS has designed it for ST Micro 8500 PLC Systemon-Chip but I would be using this not for ST Micro 8500 PLC, but to drive MOSFET with AES-Ultra96V2G and Digilent Spartan S7. 

Besides their usage as gate drive transformer, these can be used (even manufacturer recommends) in smart grids, automatic meter reading (energy, gas and water), PC home network systems, street lighting systems, home automation systems and CCTV cameras. 

So, for this design challenge, BOURNS has given both transformers which it manufacture for 'PFBR45 Series PLC Transformer' - PFBR45-ST13150S and PFBR45-SP13150S. These are differentiated by letter 'T' and 'P' in ST13150S and SP13150S. These are meant to differentiate cores but these also vary in specifications.

Specifications :

• Power Rating : 0.45 W
• Output Voltage : 15 V
• Inductance : 1 mH  +35 %, -30 %
• DC Resistance : 0.215 ohm
• Isolation Voltage : 2 kV
• Max. Interwinding Capacitance : 30 pF
• Leakage Inductance : 1.5 - 2 µH
• Max. DCR : 

(1 - 4) : 215 mΩ
(8 - 6) : 105 mΩ
(7 - 5) : 115 mΩ

• Core and Size : Ferrite, ST13 = Standard EP13
• Bobbin : Phenolic
• Wire : Copper/Insulated
• Tape : Polyester film
• Glue : Epoxy
• Terminal : Phosphor Bronze Tin 
• Operating Temperature : -40°C to 125°C
• Mounting: Surface Mount

{gallery}PFBR45-ST13150S

Thus, we have  :

1) Power Rating : 0.45 W

2) Dual Secondary Outputs :

• Each Secondary Voltage : 15 V
• Each Secondary Current : 15 mA or 0.015 A

2. BOURNS PFBR45-SP13150S

BOURNS PFBR45-SP13150S, is a Gate Drive Transformer and is the 2nd component manufactered under  'PFBR45 Series PLC Transformer'. I wont be repetiting the same above content here as only core and specifications change.

Specifications :

• Power Rating : 0.45 W
• Output Voltage : 15 V
• Inductance : 1.15 mH ±30 %
• DC Resistance : 0.5 ohm
• Isolation Voltage : 4.5 kV
• Max. Interwinding Capacitance : 30 pF
• Leakage Inductance : 1.3 µH
• Max. DCR :

(9 - 6) : 500 mΩ
(1-5) w/ (2,4) shorted : 350 mΩ

• Core and Size : Ferrite, SP13 = Special EP13
• Bobbin : Phenolic
• Wire : Copper/Insulated
• Tape : Polyester film
• Glue : Epoxy
• Terminal : Phosphor Bronze Tin 
• Operating Temperature : -40°C to 125°C
• Mounting: Surface Mount

Thus, we have  :

1) Power Rating : 0.45 W

2) Dual Secondary Outputs :

• Each Secondary Voltage : 15 V
• Each Secondary Current : 15 mA or 0.015 A

3. BOURNS BA60951CS, an Automotive Grade SMPS Flyback Transformer

Specifications :

• Power Rating : 2.25 W
• Current Rating: 1.4 A
• Primary Voltages: 7 V to 24 V
• Secondary Voltages: 15 V
• Frequency :  120 kHz
• Dielectric Strength  = 2.5 kV
• Nominal Inductance : 1.58 mH ±12 %
• Max Leakage Inductance 0.6 µH
• Operating Temperature : -40°C to 155°C
• Mounting: Through Hole

Thus, we have  :

• Power Rating : 2.25 W
• Primary Rated Current : 1.4 A
• Secondary Voltage : 15 V
• Secondary Current : 150 mA

4. BOURNS 094929, a SMPS Flyback Transformer

Specifications :

• Power Rating : 22 W
• Current Rating: 900 mA 
• Primary Voltages: 85V to 265V
• Secondary Voltages: 12 V
• Frequency :  132 kHz
• Transformation Ratio  8,78 : 1,1 : 1 : 1
• Dielectric Strength WI/WII - WIII/WIV = 4.2 kV
• Nominal Inductance : 0.94 mH ±10 %
• Max Leakage Inductance 35 µH
• Operating Temperature : -25°C to 125°C
• Mounting: Through Hole

Thus, we have  :

1) Power Rating : 22 W

2) Dual Secondary Outputs :

• Each Secondary Voltages: 12 V
• Each Secondary Current :  0.9 A   or 0.915 A (exact)

5. BOURNS 063929, a SMPS Flyback Transformer

Specifications :

• Power Rating : 4 W
• Current Rating: 650 mA or 0.65 A
• Primary Voltages: 85V to 265V
• Secondary Voltages: 6 V
• Frequency :   44 kHz to 132 kHz
• Transformation Ratio  18,6 : 1 : 1
• Dielectric Strength WI/WII - WIII/WIV = 4.2 kV
• Nominal Inductance : 3.9 mH ±10 %
• Max Leakage Inductance 200 µH 
• Operating Temperature : -25°C to 125°C
• Mounting: Through Hole

{gallery}BOURNS 063929, SMPS Flyback Transformer

Thus, we have  :

1) Power Rating : 4 W or 

2) Dual Secondary Outputs :

• Each Secondary Voltages: 6 V
• Each Secondary Current : 0.25 A or 0.33 A (exact)

6. BOURNS 063932, a SMPS Flyback Transformer  

Specifications :

• Power Rating : 6 W
• Current Rating: 250 mA or 0.25 A
• Primary Voltages: 85V to 265V
• Secondary Voltages: 12 V
• Frequency :  44 kHz to 132 kHz
• Transformation Ratio  10,6 : 6 : 1 : 1
• Dielectric Strength WI/WII - WIII/WIV = 4.2 kV
• Nominal Inductance : 1.55 mH ±15 %
• Max Leakage Inductance 60 µH 
• Operating Temperature : -25°C to 125°C
• Mounting: Through Hole

Thus, we have  :

1) Power Rating :  6 W

2) Dual Secondary Outputs :

• Each Secondary Voltage:  12 V
• Each Secondary Current :  0.25 A 

7. BOURNS 093830, a SMPS Flyback Transformer  

Specifications :

• Power Rating : 8 W
• Current Rating: 650 mA or 0.65 A
• Primary Voltages: 85V to 265V
• Secondary Voltages: 6 V
• Frequency :  132kHz
• Transformation Ratio  4 : 18,5 : 1 : 1
• Dielectric Strength WI/WII - WIII/WIV = 4.2 kV
• Nominal Inductance : 1.58 mH ±12 %
• Max Leakage Inductance 62 µH 
• Operating Temperature : -25°C to 125°C
• Mounting: Through Hole

Thus, we have  :

1) Power Rating : 8 W or 7.8W (exact)

2) Dual Secondary Outputs :

• Each Secondary Voltages: 6 V
• Each Secondary Current :  0.65 A or 0.667 A (exact)

8. BOURNS 063934, a SMPS Flyback Transformer  

Specifications :

• Power Rating : 9 W
• Current Rating:  0.37 A
• Primary Voltages: 85V to 265V
• Secondary Voltages: 12 V
• Frequency :  44 kHz to 132kHz
• Transformation Ratio 9,6 : 4,69 : 1 : 1
• Dielectric Strength = 4.2 kV
• Nominal Inductance : 0.89 mH ±10 % 
• Max Leakage Inductance 50 µH  
• Operating Temperature : -25°C to 125°C
• Mounting: Through Hole

{gallery} BOURNS 063934, SMPS Flyback Transformer

Thus, we have  :

1) Power Rating : 9 W

2) Dual Secondary Outputs :

• Each Secondary Voltages: 12 V
• Each Secondary Current : 0.37 A or 0.375 A (exact)

9. BOURNS 094931, a SMPS Flyback Transformer  

Specifications :

• Power Rating : 22 W
• Current Rating: 1.8 A
• Primary Voltages: 85V to 265V
• Secondary Voltages: 6 V
• Frequency :  66kHz to 132kHz
• Transformation Ratio 19,75 : 2,75 : 1 : 1
• Dielectric Strength WI/WII - WIII/WIV = 4.2 kV
• Nominal Inductance : 0.94 mH ±10 % 
• Max Leakage Inductance 70 µH  
• Operating Temperature : -25°C to 125°C
• Mounting: Through Hole

Thus, we have  :

1) Power Rating : 22 W

2) Dual Secondary Outputs :

• Each Secondary Voltages:  6 V
• Each Secondary Current : 1.8 A  or 1.83 A (exact)

10. BOURNS 094932, a SMPS Flyback Transformer  

Specifications :

• Power Rating : 22 W
• Current Rating: 1.2A
• Primary Voltages: 85V to 265V
• Secondary Voltages: 5V, 12V
• Frequency : 132 kHz
• Transformation Ratio 7,9 : 1 : 1 : 0,6
• Dielectric Strength WI/WII - WIII/WIV = 4.2 kV
• Nominal Inductance : 0.94 mH ±10 %
• Max Leakage Inductance 35 µH 
• Operating Temperature : -25°C to 125°C
• Mounting: Through Hole

{gallery}BOURNS 094932, SMPS Flyback Transformer

Thus, we have  :

1) Power Rating : 22  W or 21.4 W (exact)

2) Dual Secondary Outputs :

• Ist Secondary Voltages: 12  V  and Secondary Current :  1.2 A   
• 2nd Secondary Voltages:  5 V  and Secondary Current :  1.4 A

11. BOURNS 071923, a Common Mode Choke

All the transformers are properly marked with 'Manufacturer Part No ' except this one and 2 pins are not straight (the bended pin however is not an issue). You can see 071 is missing in the print.

Specifications :

• Inductance (both windings) : 22 mH ±30 %,  ∴  Inductance :  21.7 mH - 22.3 mH
• DC Current Rating : 280 mA or 0.28 A
• Maximum Resistance per winding : 3 Ω
• Operating Temperature : -25°C to 125°C
• Dielectric strength of winding-winding is 0.5 kV

12. BOURNS 093267, a Common Mode Choke

Specifications :

• Inductance (both windings) : 27 mH ± 30 %,  ∴ Inductance :  26.7 mH - 27.3 mH   
• DC Current Rating : 500 mA or 0.5 A
• Maximum Resistance per winding : 2 Ω
• Operating Temperature : -25°C to 125°C
• Dielectric strength of winding-winding is 1.5 kV

13. DURATOOL, D00413 Compartment Box

DURATOOL, D00413 Compartment Box  is a Transparent box made of plastic given in the kit to keep these flyback transformers but can be used to keep any other item and is a General Purpose Storage box. It comes with different dimensions, that is, different height, different width and different depth and material - plastic or polypropylene.

The given box is different than  DURATOOL, D00413 Compartment Box , as the last compartment No. 13, has no shelf, which is good and is 'Made In Italy'. After searching for 1 hour, I found the box given from different manufacturer 'M.Sc', MAGG Plastic organizer 165 x 112 x 31 mm - 13 compartments PP101ETN, details are given here.

But the similar kind can be found here also from MULTICOMP PRO 101FTN and its datasheet shows different box, with the same dimensions.

According to batch number, it matched 'M.Sc, MAGG Plastic organizer' box but I could not find if e14 sells of this manufacturer.

14. IDEAL POWER, 77DE-10-15M

IDEAL POWER 77DE-10-15M   is Ideal Power Limited AC to AC External Adapter. It steps down 230 VAC to 15VAC.It is rated at input frequency of only 50 Hz and not 60 Hz.

Specifications :

• Input : 230V AC, 50Hz 
• Output Voltage : 15 VAC
• Output Current : 0.67 A or 670mA
• Output Power : 10 VA or  10.05 VA (exact) or 11.5 W
• HI-POT:
  

PRI To SEC  : 4200 V
PRI To CORE : 4200 V
SEC To CORE : 2100 V

• Operating Temperature : -10°C to 40°C
• Efficiency : 70%

3. Kit Remarks

3.1 Flyback Transformer Types Sponsored

BOURNS has provided 4 types of flyback transformer, which are classified according to usage

1. Gate Drive Transformer 
2. Automotive Grade DC-DC Flyback Transformer
3. SMPS Flyback Transformer
4. Common Mode Choke

There are other kind of flyback transformers also but I m covering up of the transformers which are given in the kit. Also, I have opted for AC-AC power supply. Thus, I have

1. Gate Drive Transformers - PFBR45-ST13150S and PFBR45-SP13150S 
2. Common Mode Chokes - 071923 and 093267  
3. SMPS Flyback Transformers - BOURNS 094929, BOURNS 063929, BOURNS 063932, BOURNS 093830, BOURNS 063934, BOURNS 094931  and BOURNS 094932
4. BOURNS Automotive Grade DC-DC Flyback Transformer BOURNS BA60951CS
5. IDEAL POWER, 77DE-10-15M

All the transformers are properly marked with 'Manufacturer Part No' except BOURNS 071923, Common Mode Choke.

3.2 Operating Temperature

The operating temperature range for SMPS flyback transformers and common mode chokes is  -25°C to 125°C. All these are through-hole mounting transformers.

The operating temperature range for gate drive transformers is -40°C to 125°C. All these are SMD mounting transformers.

The operating temperature range for automotive grade DC-DC flyback transformer is -40°C to 155°C. All these are through-hole mounting transformers.

3.3 Moisture Sensitivity Level

The Moisture Sensitivity Level (MSL) for gate drive transformers and automotive Grade DC-DC flyback transformer is 1.

The MSL for SMPS flyback transformers and Common Mode Chokes is 2.

Thus, all the transformers can be typically exposed to ambient air.

3.4 Current Range

The Flyback transformer,094931 is with the highest secondary current of 1.8 A. 

The Flyback transformers PFBR45-ST13150S and PFBR45-SP13150S  are with the lowest secondary current of 15 mA. 

3.5 Hazardous Warning

All BOURNS transformers follow ROHS Directive 2015/863 and have 'Cancer Warning and Reproductive Harm' mentioned in datasheets which is based on Proposition 65  by 'The California Office of Environmental Health Hazard Assessment'.

But none of the transformers has SVHC (Substance of Very High Concern) and are RoHS and RoHS Phthalates compliant as per 2011/65/EU directive.

3.6 Standards

All BOURNS SMPS flyback transformers are in compliance with EN 62368, EN 60335 and EN 61558 standards, and VDE (Verband der Elektrotechnik, Elektronik und Informationstechnik) approved.

All BOURNS common mode chokes are EMC filter chokes and complies with EN 62368.

The automotive grade DC-DC flyback transformer is AEC-Q200 compliant.

The gate drive transformers are in compliance with EN 62368 and EN 61885 standards.

3.7  Ideal Power, 77DE-10-15M

The  Ideal Power Limited AC to AC External Adapter seems to be a linear transformer not SMPS.

3.8 Compartment Box

The given general storage compartment box is from different manufacturer and is 'Made In Italy'.  

According to the batch number, it matched 'M.Sc, MAGG Plastic organizer' box but I could not find if e14 sells of this manufacturer. Rather it resembles MULTICOMP PRO 101FTN but its datasheet shows different box, with the same dimensions. I do not know if this manufacturer has the same batch number or the datasheet is incorrectly uploaded for other box but the box seems to be from either of these manufacturer's.

4. List of Experiments

I have planned approx 25- 30 main tasks and experiments which include tutorial, 5 blogs, software files. But I would reveal these tasks and experiments in other blogs only as the experiments or the sub-experiments may change and then I would have to give extra explanations, why sub-experiment changed from this to that and others will accuse me of stories or excuses. To avoid this, I m not revealing any of these here in this blog 1.

In the next blog, I would be exploring the kit components with video along with the technology explanation taking all of the questions and disagreements and  as I have mentioned, I wont be strictly following the suggestion, so all my other blogs would be merger.

5. Experiments Preparation

For experimentation, I have downloaded latest softwares - Vivado and MPLAB X and following files from my last Design challenge- Path Programmable III, will be used for primary experimentation. Moreover, I will use LCR, multimeters and oscilloscope and other softwares which would be revealed later only.

• Ubuntu/Linux USB AMD Drivers
• Custom IP : ILA_pwmv2
• Custom IP : ILA_adc
  
• Solved:Linux/Ubuntu Installation stuck in Vivado/Vitis AMD

Mr. Abhishek Bansal

(Category:Individual,not representing anyone else)