DI-182 Design Idea

®
TOPSwitch-HX

Standard 65 W Notebook Adapter Which Meets

Requirements for Energy Star 2.0 (ES 2.0)

Application Device Power Output Input Voltage Output Voltage Topology

Notebook TOP259EN 65 W 90 – 265 VAC 19 V ±5% Flyback

Design Highlights Operation

• Very compact, low part-count
• Low profile eSIP-7C Single-Inline package
• Same thermal impedance characteristics as standard
TO-220 package
• Allows lower overall height and smaller board footprint
• Clip mounted eSIP package easily passes shock and
vibration test to IEC60068
• Highly energy efficient
• Very low no-load input power: <250 mW at 230 VAC
• High average efficiency: >87.5% meeting ENERGY STAR
v2.0 draft requirements (measured at the end of cable: 1.8 m,
18 AWG, 100 mΩ impedance)
• 132 kHz operation allows small transformer (EE28)
• Internal current-limit reduction vs line-voltage increase removes
need for secondary side current limiting used to meet power-
limited source requirements
• Accurate hysteretic thermal shutdown protection
• Timed over-load protection with automatic recovery
• Meets CISPR-22/EN55022 B conducted EMI limits
C4
2.2 nF
1 kV
The power supply design shown in Figure 1 utilizes the
TOP259EN. The TOPSwitch-HX products integrate a 700 V
MOSFET with a multi-function PWM controller in one device. The
optimized combination of switching MOSFET and integrated driver
present for low switching loss enable a highly efficient and
compact 65 W notebook power supply able to safely operate in a
sealed enclosure up to an ambient temperature of 40 °C.
The bridge rectifier BR1, at the input of the power supply, rectifies
the line input; electrolytic capacitor C2 filters the input. Fuse F1
protects against catastrophic failure. Common mode EMI is
filtered by L1, L2, L3, C3, and C11. Common-mode choke L2
filters lower frequencies while L3 filters higher frequencies.
Differential filtering is provided by the leakage inductance of L2
and X capacitor C1. As C1 has a capacitance greater than 0.1 μF,
discharge resistors R1 and R2 are required to discharge C1 after
removal of AC. To reduce differential EMI generation C5 provides
decoupling for the primary switching current.
C11 C12
2.2 nF 1 nF R16
250 VAC 100 V 33 7
C13 C14
T1 470 MF 470 MF
25 V 25 V 19 V, 3.42 A
1 EE28 FL1

BR1 D6
3KBP08M R5 MBR20100CT
100 k7 FL2
R6 1/2 W
C10 R10 RTN
33 7 VR1
22 MF 301 7 1N5248B
3 50 V 1%
4 18 V
R3 R7 D5 C8
2.0 M7 5.1 M7 BAV 100 nF
D1 19WS
DL4937 5 50 V

R11
2 M7
L3 R22 C19
12 mH R4 R8 R18
20 k7 470 pF 680 7
2.0 M7 6.8 M7 50 V
C2
L2 120 MF R12
200 MH 400 V 5.1 k7
C5
100 nF D3
400 V BAV19WS
U3A
C9 ISP817C
100 nF U3B
R1 R2 TOPSwitch-HX 25 V ISP817C
2.2 M7 2.2 M7 U1
D V TOP259EN

F1 C1 CONTROL R19
C
4A 330 nF C17 68.1 k7
275 VAC 100 nF
L R15
S X F
C6 6.8 7 R21
E
100 nF 1 k7
C3 R9 50 V C7
N 470 pF 14 k7 47 MF
250 VAC 1% 16 V
90 - 265 U2
VAC LM431 R20
L1 2% 10 k7
Ferrite Bead 1%

PI-5023-071408
Figure 1: Schematic of a 65 W Notebook Adapter Power Supply Using TOPSwitch-HX TOP259EN.

www.powerint.com July 2008

The TOP259EN, with its integrated multi-mode controller, is used Key Design Points
in a flyback configuration. It maintains output regulation by • Verify that the maximum drain voltage does not exceed 650 V
changing the duty cycle as a function of the control pin current. at high line and maximum overload. Adjust the values of C4 and
To maintain high efficiency across the whole load range, the multi- R5 as necessary.
mode controller changes between pulse width modulation and • Resistor R6 dampens high frequency ringing and improves EMI.
fixed on-time variable frequency control. To provide constant • Select the value of VR1 such that it does not falsely trigger OVP.
output overload power with changing line voltage, as line voltage VR1 should be chosen above the bias-winding voltage mea-
increases, resistors R7, R8, and R9 reduce the internal current sured under low line and full load conditions.
limit of the TOP259EN. This allows the supply to limit the output • If latching OVP is desired, select R12 as 20 Ω.
overload power to <100 VA at high line, while still delivering the • U1 does not require an insulating pad for reduced EMI. It has a
rated output at low line. tab connected to the electrically “quiet” source.
80

PI-5049-032508
The primary side’s output overvoltage protection (OVP) senses the
bias-winding voltage using Zener diode VR1. This is used to 70
provide both open-loop protection and output-overload protection QP
60
under a single-fault condition. Resistors R10 and R11 with
AV
capacitor C8 determine the delay before shutdown is triggered. 50
This prevents false triggering during startup and load transients.
40
The value of R12 selects the hysteretic shutdown behavior of U1.

dBMV
Capacitor C9 helps to filter high frequency noise that may appear 30
on the V pin.
20
The output is rectified by diode D6 which has an RC snubber (C12 10
and R16) to dampen leakage inductance ringing and reduce
0
radiated EMI. The output is filtered by capacitors C13 and C14.
-10
Feedback is derived from the output via optocoupler U3A.
-20
Resistor R18 sets the DC gain. Shunt regulator U2 has an 0.15 1.0 10.0 100.0
accurate internal voltage reference, and with resistors R19 and
MHz
R20, sets the output voltage to 19 V.
Figure 3. Conducted EMI, EN55022 B Limits. Measurements Made at 230 VAC
With 5.6 Ω Resistive Load (Output Grounded).
Diode D3 prevents loading of the V pin by the OVP circuit and also
isolates the line sense circuit from the OVP circuit. Transformer Parameters
EE28, TDK or equivalent, gapped for ALG of
Core Material
299 nH/t²
320 Bobbin Vertical 10 pin, pin 6 to pin 10 are to be removed
PI-5048-032508

Bias: 5T × 3, 30 AWG
280
Primary 1: 17T × 2, 26 AWG
240 Shield: 1T Cu foil, 1 mil thick
Input Power (mW)

Winding Details
Secondary: 6T × 4, 26 AWG-TIW
200 Shield: 1T Cu foil, 1 mil thick
Primary 2: 17T × 2, 25 AWG
160 Bias (4–5), Primary-1 (3–2), Shield (1–NC),
Winding Order Secondary (FL1–FL2), Shield (1–NC),
120 Primary-2 (2–1)

80 Primary Inductance 343 μH, ±5% at 132 kHz

Primary Resonant 1.1 MHz (minimum)
40 Frequency

0 Leakage
Inductance 4 μH (maximum)
90 115 140 165 190 215 240 265
Table 1. Transformer Parameters. (AWG = American Wire Gauge,
Input Voltage (VAC) TIW = Triple Insulated Wire, NC = No Connection)

Figure 2. No Load Input Power vs. Line Voltage.

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A
07/08 DI-182