DI-30 Design Idea TOPSwitch-GX

180 W PC Main SFX Supply

Application
PC Main

Device
TOP249YN

Power Output
180 W

Input Voltage
90 130 VAC / 180 265 VAC

Output Voltage
3.3 V / 5 V / 12 V / -12 V

Topology
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 efciency (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

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 DCMAX 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).

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. Resistors R3, R5 and R6 implement start-up undervoltage lockout, which prevents the supply from starting below
R1 330 k C4 2.2 nF 1 kV D1 1N5407

C10 1 nF 50 V 5 2 14 D7 MBR3045 R4 2.2 M 13 1 R30 1 1W 8, 9, 10 D8 MBR6045 C9 47 nF 50 V

Coupled choke L1 13 H

4 1, 2 C11 1000 F 16 V L2 0.5 H

+12 V

R3 2.2 M R5 180 k

7, 8

+5 V C13 220 F 63 V TO MAGAMP OUT (3.3 V) RTN C25 1 F 50 V LM 320 - 12 V

BR1 KBL06 CY3 2.2 nF (Safety) JP9 CX1 0.047 F 250 VAC L7 8.2 mH CX2 0.33 F 250V RT1 10 R10 560 K 1/2 W LPFC1

C2 470 F 200 V

Q4 MPSA42

R6 2.2 M LPFC2 TOPSwitch-GX U1 TOP249YN Q6 MPSA92 To AC Selector Switch VR3 BZY97C200 VR4 BZY97C180 R2 330 k VR5 BZY97C180
D L CONTROL C

C20 330 pF 50 V 11,12 3 R13 10

C12 2200 F 6.3 V

R21 270

CY4 2.2 nF (Safety)

D6 BAV20 D18 BAV20

R8 130 k 1%

R36 43.2 k 1% C22 100 pF 50 V R7 560 k

C5 1 F 100 V

C27 330 pF 50 V R11 330 D20 UF4002

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

VR19 1N5229

C3 470 F 200 V

R20 270 k

C8 0.033 F 50 V

R9 47 C6 47 F 16 V

R11 300 Q1 2N3908 R14 75 k D105 1N4148

U2 SFH615A-2

RV1 275 V, 14 mm

R30 3.3 k

U5 TL431

R19 4.12 k 1%
PI-3384-101408

R12 12 k

+12 V STBY R38 5.1 k U3 LTV817 R106 27 k

Remote ON/OFF
R37 10 k

F1 4A L G N

C7 100 nF 50 V

Q7 2N3904

C23 33 nF 50 V

Figure 1.
www.powerint.com

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 efciency 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 DCMAX reduction to prevent transformer saturation. Maintain maximum ux 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.

This particular PC SFX 12 specication delivers a larger proportion of power on the 12 V winding; efciency 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 L3 Mag Amp 6 Turns

D9 MBR2045

L4 20 H R22 3 Q2 TIP32 R34 33

L5 0.5 H

3.3 V

R23 1k R27 390 C21 1 F 50 V C18 0.1 F 50 V U8 TL431

R25 2.7 k

R24 3.84 k 1%

C14 1200 F 10 V

C15 1200 F 10 V

D11 UF4002

D10 UF4002

R26 10 k 1% RTN

RTN Figure 2. Magamp for Independent 3.3 V Secondary Regulation.

PI-3385-093002

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