TOPSwitch-GX Family (R) Extended Power, Design Flexible, EcoSmart, Integrated Off-line Switcher IC (R) FEBRUARY 2006 UPDATE TYPICAL FLYBACK APPLICATION + DC OUT - AC IN L D CONTROL TOPSwitch-GX S X C F PI-2632-060200 PRODUCT FAMILY Applications: Charger, DVD, Set-Top Box, PC Standby, Broadband Modem, Notebook Adapter, LCD Monitor. 230 VAC 15% PRODUCT Adapter Open Frame 85-265 VAC Open Frame Adapter PRODUCT HIGHLIGHTS * Extended power range for higher power applications * No heatsink required up to 34 W using P package * Tight temperature and absolute tolerance on critical parameters * Integrates high-voltage power MOSFET, PWM control, fault protection, and other control circuitry onto a monolithic IC * TO-220/262/263, DIP-8 & SMD-8 packages FEATURES & BENEFITS LOW SYSTEM COST, HIGH DESIGN FLEXIBILITY * Fully integrated soft-start for minimum stress/overshoot * Externally programmable accurate current limit * Wider duty cycle for more power, smaller input capacitor * Separate line sense & current limit pins on Y/R/F packages * Line under-voltage (UV) detection for no turn-off glitches * Line overvoltage (OV) shutdown extends line surge limit * Line feed-forward with maximum duty cycle (DCMAX) reduction rejects ripple and limits DCMAX at high line * 132 kHz frequency reduces transformer/power supply size See Data Sheet for Additional Notes and Conditions EcoSmart(R) - ENERGY EFFICIENCY * Extremely low consumption in remote OFF mode (80 mW @ 110 VAC, 160 mW @ 230 VAC) * Frequency lowered with load for high standby efficiency * Allows shutdown/wake-up via LAN/input port Y TO-220 www.powerint.com P PACKAGE OPTIONS G R DIP-8 SMD-8 TO-263 F TO-262 February 2006 TOPSwitch-GX Family Design Tools (R) POWER SUPPLY DESIGN SOFTWARE With PI ExpertTM, you're only "mouse-clicks" away from determining the key components in your next switching power supply design, including the best Power Integrations power IC and design details for the transformer! It's fast & easy...and best of all, FREE! DESIGN ACCELERATOR KITS DAKs include a working prototype power supply, sample devices, unpopulated pcb, data sheet, comprehensive engineering report & other related documentation. DAK-12 145 W, PC Main Power Supply DAK-31 180 W, PC Main Power Supply DAK-32 20 W, Universal Input, DVD Supply, No Heatsink DAK-33 45 W, 12 V LCD Power Supply DAK-34 30 W, 12 V Universal Input Power Supply TOPSwitch-GX PRODUCT & DESIGN COLLATERAL* Data Sheet Application Notes Design Ideas TOP242-250 TOPSwitch-GX Family Data Sheet AN-29 TOPSwitch-GX Flyback Quick Selection Curves AN-30 TOPSwitch-GX Forward Design Methodology AN-32 TOPSwitch-GX Flyback Design Methodology DI-12 Application: Lead Acid Battery Charger Design (16 W, Universal Input) DI-16 Application: Set-top Box (57 W, 230 VAC Input) DI-17 Application: PC Standby (17 W) DI-20 Application: PC Main ATX (145 W) DI-21 Application: LCD Monitor Adapter (45 W, Universal Input) DI-22 Application: Laptop Adapter (70 W, 19 V, Universal Input) DI-23 Application: High Speed Modem (10 W, Universal Input) DI-26 Application: DVB-T (7 W, 230 VAC Input) DI-30 Application: PC Main SFX (180 W) DI-35 Application: Audio Amplifier w/ No Heatsink (16 W - 35 W Peak, Universal Input) DI-39 Application: DVD (13 W, Universal Input) DI-41 Application: Set-top Box (43 W, 100/115 VAC Input) DI-43 Application: Medium Power AC-DC Power Supply (30 W, Universal Input) DI-55 Application: DVD w/ No Heatsink (20 W, Universal Input) DI-66 Application: LCD Monitor (45 W, 90 - 265 VAC Input) DI-67 Application: LED Arrays (17.6 W, 108 - 132 VAC, 60 Hz Input) * Downloadable from www.powerint.com 2 www.powerint.com Design Idea DI-55 TOPSwitch-GX 20 W (25 W peak) DVD Supply (R) Application Device Power Output Input Voltage Output Voltage Topology DVD TOP245P 20 W (25 W pk) 85-265 VAC 3.3 V / 5 V / 12 V / -24 V Flyback Design Highlights Operation * Simple, low cost, low part count solution * No heatsink required * Low EMI-frequency jitter allows EN55022B/FCC B compliance with simple EMI filter * High efficiency, >75% at 90 VAC * Low zero load power consumption, <100 mW at 230 VAC * Low standby power consumption, <1 W input at 0.5 W output, 230 VAC * Excellent cross-regulation * Differential and common mode surge immunity to 3 kV (EN 61000-4-5) The TOP245P selected for the design in Figure 1 is ideal for DVD and set-top applications. The P package removes the need for a heatsink while still delivering 20 W/25 W peak at an ambient temperature of 50 C. VR1 C4 33 F P6KE 400 V 130 C1 33 F 400 V F1 3.15 A J1-2 250 VAC 1 J1-1 C3 0.047 F X2 1N4007 x 4 R7 1 k 5 mH CM Choke NTRL L5 BEAD T1 EE25L 8 C2 0.01 F 1 kV 4 L2 3.3 H +12 V, 500mA D7 1N5819 R1 68 LINE RV1 275 VAC Feedback current above ~2 mA (U1 supply current) forward biases Q3 and pulls up R6. This adjusts the sink current out of the M pin, C8 2.2 nFY1 L1 RT1 t The external current limit programming and remote ON/OFF (inhibit) functions of the M pin allow current mode control and reduced switching frequency at light and no-load conditions. Current mode control is implemented by R2, Q3, R3, C16, R4 and R6. C20 180 F 25 V C15 470 F 25 V 12 L3 3.3 H 13 OPTIONAL C17 R14 470 F 1.13 k 10 V 1% R16 2.0 k R15 1% 2.4 k Q1 2SA0885 D11 SB540CT C12 1200 F 10 V D5 1N4007GP Q5 2N3906 L4 3.3 H D10 SB540CT 9 D8 1N4005 Q4 2N3904 D9 1N4005 +5 V, 2.5 A J2-3 +3.3 V, 2 A J2-6 C12 1200 F 10 V C18 470 F 10 V R17 200 RET 10,11 C9 150 F 35 V D TOPSwitch-GX U1 TOP245P CONTROL S C C6 150 F 35 V R8 1 1/2 W D12 UF4003 14 C13 47 F 25 V M R4 10 k R6 5.1 k C16 0.1 F R12 6.34 k 1% R11 20.0 k 1% -24 V, 50 mA 7 J2-1 5 R3 270 J2-2, 4, 5, 7 R13 20.0 k 1% U2 R2 18 k LTV817A C14 R10 0.1 F 10 k Q3 1N3906 D6 1N4148 C5 47 F 25 V U3 TL431 R9 10.0 k 1% PI-3648-080603 Figure 1. 20 W Multiple Output DVD Supply. www.powerint.com 3 DI-55 thereby allowing the output voltage feedback loop to control the primary switch current. TRANSFORMER PARAMETERS Resistor R6 sets the maximum current limit, while R2 and C16 provide slope compensation. The value of R4 is chosen to ensure that current does not flow into the M pin, enabling the line sensing features of the pin. The current out of the M pin falls as the load is reduced until the M pin inhibit threshold is reached. The supply then operates with a fixed 25% current limit, lowering the switching frequency to maintain regulation. This greatly reduces switching losses, maintaining high standby efficiency and low no-load power consumption. Key Design Points * For good cross-regulation, minimize transformer leakage - use foil for 3.3 V and 5 V outputs; minimize peak primary currents by designing transformer for continuous conduction mode. * Shunt regulator (temperature compensated) between 5 V and 3.3 V outputs in dotted box on schematic is optional. It is only necessary where min and max load conditions do not occur simultaneously on both outputs. * Feedback is taken from both the 3.3 V and 5 V outputs to the reference (U3) via R9, R11 and R12. The 12 V output is DC stacked on the 5 V output for enhanced regulation and voltage centering. * Primary clamp components VR1, D5, R7, R1 and C2 limit the leakage inductance induced peak drain voltage spike. * D5 is a slow recovery diode to recover some of the clamp energy. It must be a glass passivated type to guarantee a defined trr. * Use a Zener clamp for lowest zero load input power consumption. Core Material EEL25, N67 or equivalent, gap for ALG of 202 nH/T2 Bobbin 7 pin + 7 pin Winding Details Shield 1: 32T, 2 x 32 AWG Primary: 63T, 2 x 32 AWG Bias: 6T, 4 x 32 AWG Shield 2: 4T, 4 x 32 AWG 3.3 V/5 V foil: 2T + 1T, 0.12 mm foil -24 V: 13T, 2 x 32 AWG +12 V: 4T, 4 x 32 AWG Winding Order (Pin Numbers) Shield (NC-1), tape, primary (1-4), tape, bias (5-7), tape, shield 2 (13-NC), foil, (10,11-9-13), -24 V (14-10,11), 12 V (12-8) Inductance Primary: 800 H 10% Leakage: 80 H (max.) Primary Resonant Frequency 300 kHz (minimum) Table 1. Transformer Construction Information. Voltage (V) 3.3 5 12 -24 Load Regulation Range -5 -4 -3 -2 -1 0 1 2 (A) 0.3-0.6 0.3-1.2 0.1-0.2 0.03-0.05 (%) 3 4 5 6 7 Table 2. Worst Case Output Cross-Regulation - All Outputs Taken from Minimum to Maximum Loads. For the latest updates, visit www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATIONS, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. The products and applications illustrated herein (transformer construction and circuits external to the products) 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. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, EcoSmart, Clampless, E-Shield, Filterfuse, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. Copyright 2006, Power Integrations, Inc. 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