3-Phase Custom Flyback Power Supply Design

Custom Flyback Power Supply Design Specifications: A. Power Supply Topology: AC/DC Flyback Converter with external MOSFET B. Power Supply Operating Temperature Range: -40 °C to +105 °C C. Power Supply Input: 1. Input voltage range: ↓85 to ↑520 VAC and ↓120 - ↑700 VDC 2. Input voltage variation tolerance range: +30%*Input voltage & -40%*Input voltage 3. Input Frequency range: 47 ~ 64 Hz 4. Efficiency: (70%) + Kindly specify the best possible typical efficiency (%) 5. Insulation Rating (Input/Output): 4kV AC 6. Insulation Rating (Output1/Output2): 4kV AC D. Power Supply Outputs: 1. Output 1: 5V / 1.5A (Peak 2.5A) ~ 7.5W (Peak 12.5W). ----------------------------Isolation-------------------------- 2. Output 2: 12V / 0.5A ~ 6W. E. Board Dimensions: - Preferred Board Dimensions (L x W): 118 x 92 mm. Note: Size of board can be negotiated. F. Safety Specifications: Standards: EMC – Conducted and radiated emission CISPR22 / EN5022 Class B Electrostatic Discharge Immunity IEC 61000-4-2 Contact ±8kV/ Air ±15kV RF, Electromagnetic field immunity IEC 61000-4-3 30V/m Electrical Fast Transient/Burst Immunity IEC 61000-4-4 ±4kV Surge Immunity IEC 61000-4-5 L-L ±4kV RF, Conducted Disturbance Immunity IEC 61000-4-6 10V, Test Level 3 Voltage dips, Short Interruptions Immunity IEC 61000-4-11 0%, 70% Note: Please propose any possible standard that is vital for a power-supply to reliably operate according to relevant IEC standards in use case of three-phase electricity meters. G. Special considerations/requests: 1. Technical datasheet to be provided containing all relevant technical information such as: - A schematic drawing instructing the end user to integrate the power supply in a 3-phase input circuit combined outside before the input of the power supply board drawn, along with a Bill of Materials. (Kindly check file name “BPD15-KD05P12U-A power supply [login to view URL]” for reference on the second page. - All compliance standards required for Three phase smart meters to be fulfilled and to be listed in a table (IEC/EN BS) including EMC (Surge Immunity, Conducted EMI, ESD, etc.). - List typical efficiency vs different loads in a table. - List Typical no-load consumption. - Input/Output Characteristics describing all the outputs with their rated currents, voltage regulation stability and accuracy %, output voltage ripples mVp-p, startup time, hold time. - List of all built-in Input and output protection features needed such as Short-circuit protection, Line overvoltage protection, Inrush current limitation, brownout, output over-voltage & under- voltage protection, EMI filtering to meet EMC requirements, ESD protection, High surge protection, …etc. Startup time for the power-supply output rails must not exceed 2 seconds. 2. Power supply must comply with all relevant IEC/EN BS standards required in the three-phase metering market or relevant requirement. 4. The board must have the needed test points at the bottom side, to be able to test and verify operation during mass production along with guidelines explaining the function of each test point and its acceptable range in engineering units(V,A,Ohms,...etc). 5. Power supply must have at least 3 x M3 un-plated holes for support mounting to achieve mechanical stability. 6. Power supply must be made from power integration power supply tool. 7. The design files must be made with Altium. H. Deliverables: 1. Design Schematic and Layout files. 2. Design documentation on the design calculations and considerations taken to design the power supply and meet the required compliance standards. 3. Gerber file. 4. Bill of Materials in Excel .xlsx format with linked supplier part numbers and suppliers’ details for all components and transformer. 5. Transformer specification (drawings and technical data).