DI-66 Design Idea

®
TOPSwitch-GX

45 W, Universal Input, LCD Monitor

Internal Supply

Application Device Power Output Input Voltage Output Voltage Topology

LCD Monitor TOP246YN 45 W 90 – 265 VAC 5 V / 12 V Flyback

Design Highlights the use of an EER3016S core to keep the number of primary turns
• 66 kHz operation enables 0.45 W of standby output power low and to further reduce T1 leakage inductance. This reduces the
delivery with 0.9 W of input power at 230 VAC losses due to both leakage inductance and winding capacitance.
• Low no-load input power: <0.42 W at 230 VAC Low leakage inductance also allows the use of a low cost RCD
• 82% efficient (min) at 90 VAC input and 45 W output snubber (C3, R2–R4 and D5) to clamp the U1 DRAIN voltage, while
• Low component count: only 52 parts! keeping standby power consumption low. Use of a glass-passivated
• Meets CISPR22 B EMI with >10 dB of margin normal recovery diode (D5) recycles the stored leakage energy and
• No TVS required for the primary snubber increases the overall efficiency. Resistor R4 dampens drain node
ringing, and is necessary when a normal recovery diode is used.
Operation
Many of the built-in features of TOPSwitch-GX, such as line Resistor R5 sets nominal UV and OV limits to 84 V and 378 V,
UV/OV, soft start, line feed-forward, accurate current limit, and respectively. Under-voltage lockout protects the supply from
frequency jitter have been used to reduce the component count, overheating during brownout, and eliminates power-up and power-
transformer size and overall system cost of this universal input, down glitches. Overvoltage shutdown protects the power supply
flyback power supply. This design is ideal for LCD monitor from line surges.
supplies that require low standby power consumption.
Effective EMI filtering is accomplished with only five parts (L1, CX1,
The switching frequency of U1 is set to 66 kHz by connecting its CY1-CY3), due to the built-in frequency jitter function of
F pin to the CONTROL pin. Efficient 66 kHz operation results from TOPSwitch-GX.

C3 CY3
R2 10n 2.2 nF
68 k 1 kV T1
1/2 W 1
R4
10 R12 C8 L2
1/2 W 68 7 470 pF 3.3 uH 12 V, 3 A
R3 R5
R2 68 k 2M 7 10
1/2 W 5 D12
2M 1/2 W MBR20100CT C9 C10 C11
NEUT 1/2 W 680 MF 680 MF 100 MF
D1-D4 16 V 16 V 25 V
RL205 D5 L3
CY1 1N4007G 3.3 uH 5 V, 1.8 A
330 pF 2 6,7
Y1 CX1 C12 C15
GND 330 nF R6 D13 680 MF 330 nF
X2 7.5M SB540 10 V C14
1/2 W R13 R14 100 MF
C13 390 7 22 7 25 V
CY2 L1 680 MF
90 - 265 330 pF 5.3 mH 10 V
VAC 1A 8,9 RTN
Y1

C1 TOPSwitch-GX 3
100 MF U1 C6
LINE F1 RT1 D L 47 MF
400 V TOP246YN D10 R15
3.15 A 5/3 A LL4148 50 V 1.0 k7
CONTROL
250 V 4
C
U2
PC817C R16
S X F C16 10.0 k7
R8 R9 47 nF
6.8 7 330 7
R17
R7 C4 C5 2.2 k7
7.87 k7 100 nF 47MF C17
10 V 10 MF
35 V U3 R18
L4 LM431AIM3 10.0 k7
6 x 5 mm
Bead Ferrite

PI-3743-102108

Figure 1. Circuit Diagram of a TOP246 Based LCD Monitor Power Supply.

www.powerint.com October 2008

Key Design Points 1.2

PI-3744-102403
• Use 66 kHz operation to reduce standby power loss.
1.1
• To reduce the number of primary turns required for 66 kHz
operation, the Ae of the T1 core must be large. Recommended 1
cores are EER3016S and PQ2620.

Input Power (W)

0.9
• Split-primary transformer construction should be used to keep
0.8
leakage inductance to a minimum.
• Use an RCD snubber with the normal recovery diode. Size 0.7
resistors R2 and R3 for the highest value that ensures 0.6
adequate drain voltage margin under overload conditions at 230 VAC
0.5
high line. 115 VAC
0.4
0.3
80

PI-3745-102403
0.2
70 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
(QP)
60 Output Power (W)
Amplitude (dBμV)

(AV)
50 Figure 3. Pin vs. Pout, 5 V Output Loaded, No Load
on 12 V Output.
40
30
20
Transformer Parameters

10 Samwha EER3016S-PL-7, gapped for

Core Material
Quasi-Peak Scan ALG of 342 nH/t²
0
Average Scan Bobbin 10 pin, EER3016S
-10
1/2 Primary: 28T, 26 AWG
-20 Bias: 7T, 2 × 26 AWG
0.15 1 10 70 Winding Details
12 V Secondary: 4T, 2 × 25 AWG T.I.W.
Frequency (MHz) 5 V Secondary: 3T, 3 × 25 AWG T.I.W.

Figure 2. Conducted EMI, CISPR22B Limits, Maximum Load, Secondary 1/2 Primary (2–5), tape 1L, Bias (3–4), tape 2L,
Return Connected to Safety Ground, 230 VAC Input. Winding Order 12 V Secondary (10–6,7), 5 V Secondary (6,7–
8,9), tape 2L, 1/2 Primary (5–1), tape 3L
Primary Inductance 919 μH, ±10%
Primary Resonant 1.1 MHz (minimum)
Frequency
Leakage
Inductance 18 μH (maximum)

Table 1. Transformer Parameters. (AWG = American Wire Gauge,

T.I.W. = Triple Insulated Wire)

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10/08 DI-66