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| Design Idea DI-43 (R) TOPSwitch-GX 30 W, Universal Input, 12 V Supply with <250 mW No-load Application Adapter Device TOP244Y Power Output 30 W Input Voltage 85-265 VAC Output Voltage 12 V Flyback (R) Topology Design Highlights * High efficiency (79% minimum) * Low component count * Excellent input no-load consumption <200 mW at 115 VAC and <250 mW at 230 VAC input * Rugged supply includes UV/OV shutdown, thermal and short circuit protection with auto-recovery * Comfortably meets EN55022B and CISPR22B conducted EMI standards * Overload power delivery at 265 VAC limited to 160% of rated load limiting the maximum overload power of the supply. The reduced current limit allows continuous conduction mode operation with a small transformer, reducing primary and secondary peak currents, optimizing efficiency, and reducing component stress. Diode D1 and VR1 form a clamp circuit that absorbs leakage inductance energy during normal operation, with Zener VR1 clamping the voltage to a safe level. Capacitor C2 diverts some of the leakage energy from VR1, reducing its temperature and increasing overall efficiency. After clamping, reverse current flows through D1, recovering some of the clamp energy. R3 limits the reverse current in D1 and improves EMI by limiting drain voltage ringing. Resistors R9 and R10 set the output voltage. Components C10 and R8 provide compensation with R6 setting DC loop gain. Using a TL431 error amplifier gives better regulation and output voltage tolerance than a Zener reference and also provides better no-load performance due to lower (1 mA) bias current. C12 R11 470 pF 33 100 V 1/4 W D3 MBR10100 6,7 C6 680 F 35 V 9,10 D2 1N4148 C7 680 F 35 V C8 100 F 35 V RTN L2 3.3 H Operation The TOPSwitch-GX integrates many features to implement low cost, switched mode power supplies. A single resistor (R1) implements input UV/OV protection using the L pin (UV typ. 100 VDC; OV typ. 450 VDC). Resistor R4 programs the U1 current limit to 85% of nominal, and resistor R2 reduces this current limit as input voltage increases, C7 2.2 nF Y1 T1 C2 4.7 nF 1 kV R3 47 1/2 W D1 UF4005 L1 22 mH C1 100 F 400 V CX1 220 nF 250 VAC F1 3.15 A L R2 8.2 M 1/2 W D 12 V, 2.5 A 1 VR1 P6KE 200 BR1 2 A, 600 V 3 R1 2 M 1/2 W L CONTROL C 5 C3 1 F 50 V U2 ISP817C D4 1N4148 C11 10 F 35 V R6 1 k R7 15 k R9 38.3 k 1% R8 4.7 k 4 TOPSwitch-GX U1 TOP244Y S X F 85-265 VAC N R4 8.25 k 1% C4 100 nF R5 6.8 C5 47 F 10 V C10 47 nF U3 TL431 R10 10 k 1% Figure 1. TOPSwitch-GX 12 V, 30 W Universal Power Supply. DI-43 PI-3405-112702 www.powerint.com November 2002 DI-43 Optional components D4, C11, and R7 implement soft finish to limit startup overshoot. Resistor R7 discharges this softfinish capacitor at power down. TRANSFORMER PARAMETERS Core Material EF25 Nippon Ceramic NC-2H ALG of 264 nH/T2 EF25 10 pin (Miles Platts FE0100 with TBS-601) Primary: 58T x 26 AWG Bias: 2T x 26 AWG 12 V: 6T 4 x 25 AWG T.I.W. (T.I.W. = Triple Insulated Wire) 1/2 Primary, tape, 1/2 primary (1-3), tape, Bias (5-4), tape, 12 V (9-10, 6-7), tape Primary: 876 H 10% at 132 kHz, Leakage: 28 H (maximum) 570 kHz (minimum) Key Design Points * Use reflected voltage from 90 V to 120 V * Compact layout for components D3, C6 and C7 will improve efficiency. Make sure the both capacitors C6 and C7 have equal secondary loop areas to balance the ripple currents in each. * Clamp: for lowest cost use an RCD clamp replacing Zener VR1 with a power resistor. For best no-load performance, use the Zener clamp as shown. * Reference voltage: Use low current Zener secondary reference with 5 mA bias current for lowest cost. Use TL431 as shown for both better regulation accuracy and no-load consumption (due to lower bias current 1 mA). Bobbin Winding Details Winding Order (Pin Numbers) Inductance Primary Resonant Frequency Table 1. Transformer Construction Information. PI-3422-112602 .35 .30 Input Power (W) .25 .20 .15 .10 .05 0 80 120 160 200 240 280 AC Input Voltage Figure 2. PIN vs VIN Curve. For the latest updates, visit our Web site: 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, nor does it convey any license under its patent rights or the rights of others. The products and applications illustrated herein (including circuits external to the products and transformer construction) 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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch and EcoSmart are registered trademarks of Power Integrations, Inc. PI Expert is a trademark of Power Integrations, Inc. (c)Copyright 2002, Power Integrations, Inc. WORLD HEADQUARTERS AMERICAS Power Integrations, Inc. San Jose, CA 95138 USA Customer Service: Phone: +1 408-414-9665 Fax: +1 408-414-9765 e-mail: usasales@powerint.com CHINA Power Integrations International Holdings, Inc. China Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com A 11/02 EUROPE & AFRICA Power Integrations (Europe) Ltd. United Kingdom Phone: +44-1344-462-300 Fax: +44-1344-311-732 e-mail: eurosales@powerint.com KOREA Power Integrations International Holdings, Inc. Seoul, Korea Phone: +82-2-782-2840 Fax: +82-2-782-4427 e-mail: koreasales@powerint.com SINGAPORE Power Integrations, Singapore Republic of Singapore 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 TAIWAN Power Integrations International Holdings, Inc. Taipei, Taiwan Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com INDIA (Technical Support) Innovatech Bangalore, India Phone: +91-80-226-6023 Fax: +91-80-228-9727 e-mail: indiasales@powerint.com APPLICATIONS FAX World Wide +1-408-414-9760 www.powerint.com |
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