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Design Idea DI-16 (R) TOPSwitch-GX 57 W, 230 VAC,
Multi-output Set-top Box Power Supply
Application Set-top Box Device TOP246Y Power Output 43 W cont./57 W peak Input Voltage 180-265 VAC Output Voltage 3.3 V / 5 V / 12 V / 18 V / 33 V
(R)
Topology Flyback
Design Highlights
* High efficiency, >75% at 180 VAC * Good cross-regulation with no linear regulators * Line undervoltage detection (UV) and overvoltage (OV) power system surge protection * Meets CISPR22B/EN55022B conducted EMI limits * Differential and common mode surge immunity to 4 kV (EN61000-4-5) * 100 kHz ring wave immunity to 4 kV (IEEE C62.41)
Key Design Points
* R1 (2 M, 0.5 W) sets UV at 100 VDC and OV at 450 VDC. A 0.5 W resistor is required to give a voltage rating greater than 350 VDC. * Integrated OV shut-down protects against long duration line voltage surges (common in some countries). During shutPERFORMANCE SUMMARY Output Power: 45 W Cont./ 57 W Peak Regulation: 3.3 V: 5% 5 V: 5% 12 V: 7% 18 V: 7% 33 V: 8% Efficiency: 75% No-Load Consumption: 0.6 W
C5 R2 68 k 1 nF 2 W 1 kV T1
18
down, the drain voltage does not exceed the DC input voltage (drain does not switch), allowing the AC rail to rise to 495 VAC (700 VDC BVDSS rating) without damaging the TOPSwitch-GX. * Transformer T1 is constructed using a slotted bobbin, enabling automated transformer winding and assembly. * The transformer turns ratio is optimized (including output diode forward drops) to minimize the output voltage error between the 3.3 V and 5 V outputs. * Feedback is taken from both the 3.3 V and 5 V outputs to the reference (U3) via R10, R11 and R13. Other output voltages are set by the transformer turns ratio. The 12 V, 18 V, and 33 V outputs are DC-stacked on the 5 V output for enhanced regulation and voltage centering. Pre-load resistor R14 is required to maintain regulation of the 33 V output when lightly loaded.
R6 10 D8 UF5402 D9 UF5402
D7 UF4003 C7 47 F 50 V C9 1000 F 25 V
L6 33 H, 0.2 A L2 3.3 H, 5 A L3 3.3 H, 5 A C8 10 F 50 V C10 100 F 25 V
33 V, 0.03 A
17
18 V, 0.5 A 12 V, 0.6 A/1.8 A pk
16
10
L7 Bead C24 R15 0.1 F 10 50 V
C11 390 F 35 V L4 3.3 H 5A C13, C14 1000 F 35 V C16, 17 1000 F 35 V L5 3.3 H 5A C15 220 F 16 V
C12 100 F 25 V
R14 2.7 k 0.5 W 5 V, 3.2 A
C6 2.2 nF Y1
1
11
D1-D4 1N4007V 1 A, 1000 V D2 D1 D5 UF4005 D4 L1 20 mH 0.8 A C1 0.1 F X2 RV1 275 V 14 mm F1 3.15 A
L
180 - 265 VAC
14, 15
D10 BYV32-200 D11 MBR1045
3.3 V, 3 A
VR1 P6KE200
3, 4 12, 13
C18 220 F 16 V
RTN
D3
C2 68 F 400 V R1 2 M 1/2 W
5 8
R7 150 D6 1N4148 C3 1 F 50 V U2 LTV817 R8 1 k C19 0.1 F 50 V R10 9.53 k 1% R13 15 k 1%
9
D
L
TOPSwitch-GX
C
U1 TOP246Y RT1 10 1.7 A R4 9.09 k 1%
S
CONTROL
X
F
t
C3 0.1 F 50 V
R3 6.8 C5 47 F 16 V
C20 22 F 50 V
R9 3.3 k U3 TL431CLP R11 10 k 1% PI-3395-100102
N
Figure 1. TOPSwitch-GX 60 W Set-top Box Output Power Supply.
DI-16
www.powerint.com
December 2002
DI-16
* A soft-finish capacitor (C20), eliminates start-up output overshoot. * Second stage LC post-filtering was used on all outputs for low output ripple (L2-6 and C8, 10, 12, 15 and 18). * Primary clamp components VR1 and D5 limit the leakage inductance induced peak drain voltage to a safe value. R2 and C5 reduce power dissipation in VR1. * Frequency jitter provides large EMI margins with simple filtering. WINDING INSTRUCTIONS
Slot 1 - Start Pin 5 Slot 2 - Start Pin 11 Start Pin 14 Start Pin 16 Start Pin 17 Start Pin 18 Slot 3 - Start Pin 3 Start Pin 8 Slot 4 - Start Pin 11 Start Pin 14 Start Pin 14 Slot 5 - Start Pin 5 Slot 6 - Start Pin 11 Start Pin 15 Start Pin 15 Start Pin 16 Slot 7 - Start Pin 4 Slot 8 - Start Pin 11 Start Pin 15 Start Pin 16 Start Pin 17 Start Pin 18 Slot 9 - Start Pin 5 26T 1T 2T 4T 3T 6T 26T 7T 1T 2T 2T 26T 1T 2T 2T 4T 26T 1T 2T 4T 3T 6T 26T 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25mm 0.25mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm 0.25 mm Finish Pin 3 Finish Pin 14 Finish Pin 12 Finish Pin 10 Finish Pin 16 Finish Pin 17 Finish Pin 1 Finish Pin 9 Finish Pin 14 Finish Pin 12 Finish Pin 12 Finish Pin 4 Finish Pin 15 Finish Pin 13 Finish Pin 13 Finish Pin 10 Finish Pin 1 Finish Pin 15 Finish Pin 13 Finish Pin 10 Finish Pin 16 Finish Pin 17 Finish Pin 4
TRANSFORMER PARAMETERS
Core & Bobbin Primary Inductance (pins 1-5, with pins 3-4 shorted together, all other windings open) Primary Resonant Frequency (same test conditions as above) Leakage Inductance (pins 1-5 with pins 3-4 shorted, pins 10-18 shorted) Orega SMT 18 core/bobbin set, gappped for 180 nH/T2
487 H 10%
2 MHz (minimum)
15 H (maximum)
Table 2. Transformer Electrical Specifications.
PI-2891-062502
80 70 60
QP Limit Line AV Limit Line
Amplitude (dBV)
50 40 30 20 -10 0 -10 -20 0.15 1
Quasi-Peak Scan Average Scan
EN_V_QP EN_V_AV
10
30
Frequency (MHz)
Table 1. Transformer Build Information.
Figure 2. Conducted EMI (230 VAC, 43 W).
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. (c)Copyright 2002, Power Integrations, Inc.
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B 12/02
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