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DI-30 Design Idea TOPSwitch-GX

®

180 W PC Main SFX Supply

DI-30 Design Idea TOPSwitch-GX ® 180 W PC Main SFX Supply Application Device Power Output Input

Application

Device

Power Output

Input Voltage

Output Voltage

Topology

PC Main

TOP249YN

180 W

90 – 130 VAC / 180 – 265 VAC

3.3 V / 5 V / 12 V / -12 V

Forward

Design Highlights

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 (DC MAX ) prevents transformer saturation for fault and transient loads

Uses conventional magamp for 3.3 V output

Meets CISPR22B/EN55022B conducted EMI

Operation 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, C3) balancing circuit, operating only as needed to minimize zero-load power consumption.

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.

The reset circuit works in conjunction with the DC MAX reduction circuit (R8, R36, C22, VR19 and D18) to limit the maximum duty cycle and prevent transformer saturation under fault and transient conditions.

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).

Resistors R3, R5 and R6 implement start-up undervoltage lockout, which prevents the supply from starting
Resistors R3, R5 and R6 implement start-up undervoltage
lockout, which prevents the supply from starting below
C10
1 nF
Coupled
50 V
choke
L1
13
H
5
4
+12 V
2
14
C11
C4
7, 8
1, 2
R1
R3
D7
1000
F
2.2 nF
330 k
2.2
M
MBR3045
C9
16 V
L2
1
kV
R4
47
nF
0.5 H
2.2 M
13
50
V
6
3
+5 V
R5
D1
R30
180 k
BR1
1N5407
1
Q4
1
KBL06
1
W
C13
C2
MPSA42
220 F
470 F
C12
8,
9, 10
R21
63 V
200
V
D8
2200
F
270
CY3
LPFC1
C20
MBR6045
6.3 V
R6
TO
2.2 nF
330 pF
2.2
M
MAGAMP OUT
(Safety)
50 V
(3.3 V)
LPFC2
11,12
RTN
CY4
JP9
TOPSwitch-GX
C27
C24
2.2 nF
3
D6
330 pF
330
F
U1
R13
BAV20
C5
(Safety)
25
V
C25
50 V
TOP249YN
10
R18
1 F
CX1
D18
Q6
1 F
100 V
R11
4.74
k
50 V
R8
R36
0.047
F
4
BAV20
MPSA92
330
1%
LM
130 k
43.2 k
250 VAC
- 12 V
320
To AC Selector
Switch
1%
1%
R15
D20
1.8 k
L7
UF4002
R7
VR19
8.2 mH
VR3
D
L
C22
560 k
1N5229
C17
CX2
R20
BZY97C-
100 pF
100
nF
CONTROL
0.33
F
270 k
C3
200
50 V
50
V
C
250V
470
F
R16
VR4
U2
200
V
R11
1 k
R10
BZY97C-
SFH615A-2
RT1
300
180
S
X
F
C8
560 K
C16
R9
10
1/2 W
0.033 F
50 V
100
nF
R17
47
Q1
VR5
50 V
15 k
2N3908
RV1
BZY97C-
R2
D105
275 V, 14 mm
180
330 k
R30
C6
1N4148
R14
U5
3.3
k
47
F
R19
75 k
TL431
16
V
4.12
k
1%
PI-3384-101408
+12 V STBY
R12
R38
R106
12 k
5.1 k
27
k
Remote
U3
LTV817
ON/OFF
F1
C7
Q7
4 A
100 nF
2N3904
C23
50
V
R37
33
nF
10
k
50
V
L
GN

www.powerint.com

Figure 1.

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

October 2008

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 2 mW by supplying external current to the CONTROL pin from the +15 V standby supply. Resistor R11 is required to allow external bias feed.

Key Design Points

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 clamp/ reset circuit to maintain drain voltage <600 V and DC MAX 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 Applica- tion Note AN-30 for details on designing forward converters with TOPSwitch-GX.

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.

Due to the complexity of this design it is not possible to include all details in this Design Idea. An Engineering Prototype Report (EPR-31) with additional information is available. For updates and all other information please refer to Power Integrations' Web site.

FROM MAIN CONVERTER 5 V WINDING D9 L4 L5 MBR2045 20 H 0.5 H 3.3
FROM MAIN
CONVERTER
5 V WINDING
D9
L4
L5
MBR2045
20
H
0.5 H
3.3 V
L3
R22
Mag Amp
3
6 Turns
R23
R25
R24
1 k
2.7 k
3.84 k
Q2
C14
1%
C15
TIP32
1200
F
1200
F
R27
C18
R34
10 V
10 V
390
0.1
F
33
50 V
D11
C21
UF4002
D10
R26
1
F
U8
UF4002
10 k
50 V
TL431
1%
RTN
RTN
PI-3385-093002
Figure 2.
Magamp for Independent 3.3 V Secondary Regulation.

Power Integrations 5245 Hellyer Avenue

San Jose, CA 95138, USA. Main: +1 408-414-9200

Customer Service

Phone: +1-408-414-9665 Fax: +1-408-414-9765 Email: usasales@powerint.com

On the Web www.powerint.com

D

10/08

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 LIMITATION, 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, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,

PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.

©2005, Power Integrations, Inc.

DI-30