Design Idea DI-30

TOPSwitch-GX
180 W PC Main SFX Supply
Application

Device

Power Output

PC Main

TOP249Y

180 W

Output Voltage

Input Voltage

90-130 VAC / 180-265 VAC 3.3 V / 5 V / 12 V / -12 V

180 W cont. (200 W peak) in PC SFX form factor

Includes passive power factor correction (PFC)
TOPSwitch-GX integrated features enable extremely low
component count
Meets 1 W standby spec (0.91 W input, 0.5 W output)
High efficiency (71% minimum)
Integrated line undervoltage and overvoltage detection
Low EMI due to frequency jitter
SOURCE referenced TO-220 tab lowers conducted EMI
Maximum duty cycle reduction (DCMAX) prevents transformer
saturation for fault and transient loads
Uses conventional magamp for 3.3 V output
Meets CISPR22B/EN55022B conducted EMI

Resistors R3, R5 and R6 implement start-up undervoltage

lockout, which prevents the supply from starting below
180 VDC. Components R4, R14, Q1 and R30 implement an
independent undervoltage using the X pin, which allows the
supply to continue delivering power all the way down to
140 VDC (increasing holdup time). Resistor R7 provides
additional hysteresis.
The primary side components D1, VR3-5 and C4, along with
secondary side C9 and R30, implement the Zener/capacitor
reset/clamp circuit. This circuit provides reset voltage for the
transformer and clamps the DRAIN pin voltage to a safe level
(<~600 V) under all conditions.

Operation

The reset circuit works in conjunction with the DCMAX

reduction circuit (R8, R36, C22, VR19 and D18) to limit the
maximum duty cycle and prevent transformer saturation
under fault and transient conditions.

TOPSwitch-GX integrates many features designed for use with

forward converters. Passive power factor correction (PFC) is
implemented using inductors LPFC1 and LPFC2. Transistors
Q4, Q6, R1, R2, R3, R5, and R6 form an active capacitor (C2,

C10
1 nF
50 V
5
R1
330 k

LPFC1

CY3
2.2 nF
(Safety)

C2
470 F
200 V

Q4
MPSA42

14

C4
2.2 nF
1 kV

R4
2.2 M

CX1
0.047 F
250 VAC

8, 9, 10
C20
330 pF
50 V
11,12

R6
2.2 M

L7
8.2 mH
CX2
0.33 F
250V
RT1
10

TOPSwitch-GX
U1
TOP249
Q6
MPSA92
To AC Selector
Switch

C3
470 F
200 V

R10
560 K
1/2 W

R8
130 k
1%

VR3
BZY97C200
VR4
BZY97C180

CONTROL
C

VR5
BZY97CR2
180
330 k

RV1
275 V, 14 mm

R36
43.2 k
1%

C8
0.033 F
50 V

R30
3.3 k

R7
560 k

+5 V

C12
2200 F
6.3 V

D6
BAV20
D18
BAV20

C5
1 F
100 V

C27
330 pF
50 V
R11
330
D20
UF4002

VR19
1N5229

R14
75 k

C24
330 F
25 V
R18
4.74 k
1%
R15
1.8 k
C17
100 nF
50 V
R16
1 k
C16
100 nF R17
50 V 15 k

U2
SFH615A-2

D105
1N4148

C13
220 F
63 V

R21
270

Q1
2N3908

+12 V STBY

Q7
2N3904

U5
TL431

TO
MAGAMP OUT
(3.3 V)
RTN
C25
1 F
50 V
LM
320

- 12 V

R20
270 k

R19
4.12 k
1%
PI-3384-120902

R106
27 k

R38
5.1 k

Remote
ON/OFF

U3
LTV817
C7
100 nF
50 V

+12 V
C11
1000 F
16 V L2
0.5 H

1, 2

D8
MBR6045

R11
300

R9
47
C6
47 F
16 V

R12
12 k

F1
4A

R13
10

C22
100 pF
50 V

R30
1
1W

CY4
2.2 nF
(Safety)

C9
47 nF
50 V

13

R5
180 k

D1
1N5407

Coupled
choke
L1
13 H

7, 8

D7
MBR3045

R3
2.2 M

LPFC2
JP9

Forward

C3) balancing circuit, operating only as needed to minimize

zero-load power consumption.

Design Highlights

BR1
KBL06

Topology

C23
33 nF
50 V

R37
10 k

Figure 1. 180 W (200 W pk.) PC Main Power Supply Schematic (Note: Schematic does not include transformer Y-capacitor).
DI-30

www.powerint.com

December 2002

DI-30
clamp/reset circuit to maintain drain voltage < 600 V and
DCMAX reduction to prevent transformer saturation.
Maintain maximum flux density on transformer (T1)
< 2500 gauss.
Check for balanced currents on coupled inductor (L1) for
all load combinations.
Use PI Expert (PIXls) Design Spreadsheet and refer to
Application Note AN-30 for details on designing forward
converters with TOPSwitch-GX.

The components R12, C7, R38, Q7, C23, R37, U3, R106 and
D105 implement the remote ON/OFF drive circuit. During
the ON state, U3 and hence Q7 conduct, pulling the X pin to
SOURCE via resistor R12 (which sets the current limit).
During the OFF state, U3 and Q7 are off, allowing the X pin
to be pulled high by the +15 V standby supply via R38 and R12
and putting the TOPSwitch-GX into the OFF state. Components
R38 and D105 reduce device consumption to around 2mW by
supplying external current to the CONTROL pin from the
+15 V standby supply. Resistor R11 is required to allow
external bias feed.

This particular PC SFX 12 specification delivers a larger

proportion of power on the 12 V winding; efficiency would be
lower if that power were drawn from the 3.3 V output.

Key Design Points

Due to the complexity of this design it is not possible to include

all details in this Design Idea. An Engineering Prototype Report
(EPR) will be available for this design Dec. 2000. For updates
and all other information please refer to Power Integrations'
Web site.

The passive PFC inductors (LPFC1 and LPFC2) are

constrained by both thermal and efficiency requirements.
Design of these inductors is not covered in this Design Idea.
Transformer reset: Use recommended Zener/capacitor
D9
MBR2045
FROM MAIN
CONVERTER
5 V WINDING

L4
20 H

L5
0.5 H
3.3 V

L3
Mag Amp
6 Turns

R22
3
Q2
TIP32
R34
33
D11
UF4002

R23
1 k
R27
390
C21
1 F
50 V

D10
UF4002

R25
2.7 k

R24
3.84 k
1%

C18
0.1 F
50 V
U8
TL431

RTN

R26
10 k
1%

C14
1200 F
10 V

C15
1200 F
10 V

RTN
PI-3385-093002

Figure 2. Magamp for Independent 3.3 V Secondary Regulation.

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. Copyright 2002, Power Integrations, Inc.
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