Flyback Bias Winding and Transformer Leakage

Version 4
SHEET 1 4756 5888

WIRE 1136 944 976 944
WIRE 976 992 976 944
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144 1712 -80 1712
608 1728 608 1616
800 1728 800 1600
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432 1792 352 1792
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352 1824 352 1792
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1344 2000 1344 1936
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-96 2016 -336 2016
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-1024 2032 -1024 1984
576 2048 304 2048
688 2048 656 2048
752 2048 688 2048
1424 2064 1424 2032
-240 2080 -240 1936
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1344 2176 1264 2176
1424 2176 1424 2144
1424 2176 1344 2176
-16 2208 -112 2208
432 2240 432 2176
480 2240 432 2240
800 2240 800 2064
800 2240 560 2240
1840 2272 1840 1152
432 2288 432 2240
688 2288 688 2048
800 2288 800 2240
1904 2288 1888 2288
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-112 2304 -192 2304
1344 2304 1344 2176
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1920 2336 1888 2336
2016 2336 2000 2336
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144 2432 144 2272
144 2432 -64 2432
432 2432 432 2352
432 2432 144 2432
688 2432 688 2368
688 2432 432 2432
800 2432 800 2368
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WIRE 1568 2432 1344 2432
WIRE 1840 2432 1840 2352
WIRE 1840 2432 1568 2432
WIRE 144 2448 144 2432
WIRE -464 2544 -464 2016
WIRE 1264 2544 1264 2176
WIRE 1264 2544 -464 2544
FLAG 144 2448 0
FLAG 352 1920 0
FLAG 448 1264 0
FLAG 1904 2288 0
FLAG 2016 2336 0
FLAG 2016 1120 VOUT
FLAG 304 1648 0
FLAG -400 1840 0
FLAG -32 1584 0
FLAG -368 1552 0
FLAG -256 1552 0
SYMBOL cap -208 2320 R0
SYMATTR InstName C15
SYMATTR Value 3n
SYMATTR SpiceLine Rser=0.03
SYMBOL res -208 2160 R0
SYMATTR InstName R24
SYMATTR Value 2330
SYMATTR Value 47
SYMBOL voltage 352 1808 R0
WINDOW 123 0 0 Left 2
SYMATTR InstName V11
SYMATTR Value 5
SYMBOL res 464 2256 R270
WINDOW 0 32 56 VTop 2
WINDOW 3 0 56 VBottom 2
SYMATTR Value 700
SYMATTR Value 4300
SYMBOL cap 416 2288 R0
SYMATTR Value 390p
SYMBOL nmos 752 1968 R0
WINDOW 3 -99 -21 Left 2
SYMATTR Value STW11NM80
SYMATTR InstName M2
SYMATTR Value 1
SYMATTR Value 0.36

SYMATTR Value 33k
SYMBOL ind2 784 1504 R0
SYMATTR InstName L3
SYMATTR Value 1.5e-3
SYMATTR Type ind
WINDOW 0 -24 150 Left 2
SYMATTR InstName L4
SYMATTR Value 79
SYMATTR Type ind
SYMBOL schottky 1024 1168 R270
SYMATTR InstName D2
SYMATTR Value MBRS1100
SYMATTR Description Diode
SYMATTR Type diode
SYMATTR Value 220
SYMATTR Value 33
SYMBOL voltage -2160 1776 R0
SYMATTR Value SINE(0 325 50)
SYMATTR Value 2k5
SYMATTR Value 14k5
SYMATTR Value 100n
SYMATTR Value 100
SYMATTR Value 17
SYMBOL sw 1840 2256 M0
SYMATTR InstName S4
SYMBOL voltage 1904 2336 M90
WINDOW 3 129 -281 VRight 2
SYMATTR Value PWL(0 -1 180m -1 180001u +1 230500u +1 230501u -1)

SYMATTR Value 4k7
SYMATTR Value 4n7
SYMATTR Value 10k
SYMATTR Value 220p
SYMBOL PowerProducts\\LT1244 144 2112 R0
SYMATTR InstName U1
SYMBOL npn -976 1744 R0
SYMATTR InstName Q1
SYMATTR Value 2N5550
SYMBOL npn -864 1872 R0
WINDOW 0 78 -15 Left 2
SYMATTR InstName Q2
SYMBOL zener -1008 2096 R180
SYMATTR InstName D1
SYMATTR Value BZX84C10L
SYMATTR Type diode
WINDOW 3 -123 -3 Left 2
SYMATTR InstName D3
SYMATTR Type diode
SYMATTR InstName R1
SYMATTR Value 2.2E6
SYMATTR InstName R2
SYMATTR Value 330k
SYMATTR InstName R3
SYMATTR Value 820K
SYMATTR InstName C1
SYMATTR Value 10

SYMATTR InstName L1
SYMATTR Value 567
SYMATTR Type ind
SYMBOL schottky 304 1408 R90
SYMATTR InstName D4
SYMATTR Value MBRS1100
SYMATTR Type diode
SYMATTR InstName R4
SYMATTR Value 10
SYMBOL schottky -768 2016 R270
SYMATTR InstName D5
SYMATTR Type diode
SYMBOL diode -1840 1744 R180
SYMATTR InstName D6
SYMATTR Value MUR460
SYMATTR InstName D7
SYMATTR InstName D8
SYMATTR InstName D9
SYMATTR InstName C2
SYMATTR Value 1
SYMATTR InstName R5
SYMATTR Value 150
SYMATTR InstName C3
SYMATTR Value 470p
SYMBOL diode 624 1616 R180
SYMATTR InstName D10
SYMATTR Value UPSC600
SYMATTR InstName C4
SYMATTR Value 270p
SYMATTR InstName R6
SYMATTR Value 33k
SYMATTR InstName C5
SYMATTR Value 100p
SYMATTR InstName R7
SYMATTR Value 150
SYMATTR Type diode
SYMATTR Type diode
SYMATTR InstName R8
SYMATTR Value 39K
TEXT 664 1072 Left 3 !K1 L3 L4 L1 0.99
TEXT 1248 952 Left 2 ;Higher voltage\ndiode would be\nused.
TEXT 1968 2504 Right 2 !.model sw sw(Ron=1m)
TEXT 1856 2080 Left 4 ;SHORT\nCIRCUIT\nAT 180ms\ntill 230ms.
TEXT 1496 600 Left 4 ;Isolated feedback is actually\nomitted for simulation spe
ed.
TEXT -1112 2472 Left 3 ;These BJTs would instead\nbe something like 400V rated\n
MPSA44 parts. -Note that these\n400V BJTs have low hfe, and\nso the Darlington i
s used as here..\n-which reduces dissipation in the \nR/Zener circuit during the
SMPS\noperation.
TEXT 1576 1200 Left 5 ;Vout=17V
TEXT 1280 2776 Left 2 !.tran 0 230m 0 startup
TEXT -2152 1544 Left 5 ;UK\nMAINS
TEXT -480 1648 Left 3 ;Bias rail\ncapacitor
TEXT -1296 1688 Left 5 ;Linear \nstartup\nregulator.
TEXT -328 776 Left 5 ;Leakage spike RC\nfilter...this prevents \novervoltage on
the \nbias rail due to ringing\nwith the leakage inductance.
TEXT -312 1736 Left 4 ;BIAS RAIL
TEXT -1592 672 Left 2 ;Note that the startup regulator must\nbe made such that i
t is NOT capable\nof supplying the running current of the\nLT1244 controller IC.
-If it was capable\nof that then it would be too dissipative.\nThe idea is that
the linear startup regulator simply\ncharges up the Bias Rail Capacitor to the
starting VCC\nvoltage of the LT1244...at that point the Bias capacitor\nmust be
big enough so that the Bias Coil starts supplying\nthe LT1244 before the Bias c
apacitor discharges below\nthe turn-OFF threshold of the LT1244.
TEXT 328 1664 Left 4 ;Bias\nCoil
TEXT -1640 1176 Left 5 ;DC BUS

TEXT -3072 832 Left 2 ;Note that the startup regulator shown here is not\nperfec
t. In some (improved) startup regulators, once the bias\ncoil starts powering t
he bias rail, then the series diode (in this case\nD5) gets reverse biased by t
he voltage on the bias rail, and as such\nthere is no current flow through the c
ollector of the BJT of the startup\nregulator once the SMPS has got up and runni
ng. -and this means there\nis then no dissipation in that BJT.\nThe startup re
gulator shown here does not have this feature, and unfortunately,\nthe BJT still
provides a millliamp or so even whilst the SMPS is fully up and \nrunning.\nAs
you know, the tolerance on the zener voltage and the Vbe voltage dont help\nyou
when trying to design a startup regulator as shown here. Of course, it also\ndoe
snt help that the actual bias rail voltage itself will have a tolerance \nto it
.\nAnother problem with the bias rail is that when the SMPS goes into light load
or no_load,\nthe bias rail is sometimes in danger of dropping out. -Often an ex
tra turn or \nmore has to be added to the bias coil in order to ensure that this
does not happen.
TEXT 384 536 Left 4 ;You need to be sure that with the worst case\ntolerance lea
kage inductance, the bias coil\nRC filter damps out any possibility of overvolta
ge\non the bias rail. Often, in cases of output short\ncircuit, the R/Zener clam
p is needed to prevent\novervoltaging the PWM controller IC and/or\nbias rail ca
pacitor.
TEXT -392 32 Left 2 ;The leakage inductance is particularly energised\nwhen some
one turns the SMPS on/off/on....this is because\nat the "second on-coming" the D
C bus can be low, and if the \nUVLO isn't well implemented, then the primary pea
k switching current\ncan be higher meaning that the leakage inductor peak curren
t is also \nhigher, and thus more energy is in the leakage and it can ring\nmuch
and can potentially cause an overvoltage on the primary Bias rail.\n-Leading p
otentially to damage to the PWM controller IC, and/or the\ncapacitor on that rai
l.
TEXT -1056 376 Left 4 ;If the bias coil leakage ring is particularly high\nin it
s peak value, then the bias rail capacitor\ncan potentially get peak charged to
a \nvoltage which is above the allowable\nmaximum voltage on the VCC pin of the
\nPWM controller IC.
TEXT 128 1488 Left 2 ;Higher voltage\ndiode would be\nused.
TEXT -2400 -184 Left 5 ;AN RC FILTER CAN BE NECESSARY NEAR THE BIAS COIL DIODE\n
SO AS TO STOP PEAK CHARGING OF THE BIAS RAIL\nTO A VOLTAGE ABOVE THAT ALLOWED FO
R THE PWM\nCONTROLLER IC. \nThe peak charging is from the peaks of the resonant
ring with the\nleakage inductance.
TEXT 2168 1224 Left 2 ;Note when the output goes short circuit at 180ms,\nthe di
ssipation in the RCD clamp resistor dramatically\nincreases, also the peak FET d
rain voltage dramatically\nincreases. -This is why you need the Controller IC to
have \na short circuit shutdown facility built into it (alternatively you \nsho
uld add circuitry which gives this protection).\nThe shutdown circuitry usually
shuts down the SMPS\nif during any ~800ms interval, the output is never at its
\nregulation level.
TEXT -720 1232 Left 2 ;The R/Zener is needed \nto prevent the LT1244 \ncontrolle
r from getting \novervoltaged during say \na short circuited output.
TEXT 904 -48 Left 5 ;Beware of overvoltages and high dissipations\nin snubber re
sistors etc due to excessive leakage\nringing in times of output short circuit o
r overload.
TEXT -1824 -904 Left 7 ;THIS SHOWS AN OUTPUT SHORT CIRCUIT HAPPENING AT 180ms,\
nAND THEN THE OVERVOLTAGES AND HIGH RCD CLAMP RESISTOR \nDISSIPATIONS DUE TO EXC
ESSIVE TRANSFORMER LEAKAGE \nINDUCTANCE RINGING ARE SEEN.
TEXT -816 -1144 Left 7 ;OFFLINE FLYBACK SMPS
TEXT -1184 3104 Left 7 ;RE-RUN THIS SIMULATION WITHOUT LEAKAGE\n(ie put K=1), A
ND SEE HOW THE SAID PROBLEMS\nGO. (obviously you cannot physically wind a transf
ormer\nto have zero leakage, though you can optimise the winding\nfor lower leak
age)
TEXT 528 1760 Left 2 ;A TVS may be needed\nacross the RCD clamp \nresistor, in o
rder to quell \novervoltage there.
TEXT 1584 1656 Left 5 ;LOAD

TEXT -2776 360 Left 3 ;Note that the amount of ringing and overvoltage\ndepends
on the amount of leakage. This is why\nits worth doing interleaved winding for l
ow leakage,\nalso, designing the transformer using only full-layer\nturns so tha
t the tolerance range on the leakage\nfrom part to part is kept within limits.
LINE Normal 432 1664 432 1472 2
LINE Normal 736 1648 736 1648 2
LINE Normal 736 1648 736 1648 2
LINE Normal 736 1648 736 1648 2
LINE Normal 880 1648 880 1456 2
CIRCLE Normal -608 2272 -1184 1376 2
CIRCLE Normal 176 1664 -160 1312 2

Flyback Bias Winding and Transformer Leakage

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Flyback Bias Winding and Transformer Leakage

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Version 4

SHEET 1 4756 5888

-32 1584 -32 1552

-16 2016 -96 2016

WIRE 1568 2432 1568 1776

SYMBOL res 672 2272 R0

SYMATTR Value PWL(0 -1 180m -1 180001u +1 230500u +1 230501u -1)

SYMATTR SpiceLine Rser=0.03

TEXT -1640 1176 Left 5 ;DC BUS

TEXT 1584 1656 Left 5 ;LOAD

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