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| Design Idea DI-39 (R) TOPSwitch-GX 13 W, Universal Input DVD Supply with 70 mW No-load Application DVD Device TOP244P Power Output 13 W (17 W pk) Input Voltage 85-265 VAC Output Voltage 3.3 V / 5 V / 12 V / -12 V Topology Flyback (R) Design Highlights * * * * * * * High efficiency multi-ouptut flyback (77% minimum) Topology scalable to higher powers Excellent cross-regulation Excellent input no-load consumption <70 mW input 132 kHz switching frequency allows smaller transformer Frequency jitter eliminates common-mode EMI choke >10 dB margin against CISPR22-B conducted EMI with artificial hand grounding The supply operates at full frequency at high and medium power and reduces frequency at light loads. Components D9 and C10 rectify and filter the bias voltage. TOPSwitch-GX frequency jitter allows conducted EMI compliance without a common-mode choke, using only capacitors C1, C4 and inductor L1 as an EMI filter. Components D5 and C2 form a capacitor clamp circuit absorbing leakage inductance energy during normal operation. Zener VR1 clamps the voltage to a safe level during abnormal and transient conditions. After clamping, reverse current flows through D5, recovering some of the energy. Resistor R5 limits the reverse current and, with R7, improves EMI by limiting the ringing on the drain. Continuous mode operation allows reduced primary and secondary peak currents, optimizing cross regulation and load regulation by minimizing leakage inductance induced voltage shifts. Resistors R15 and R16 share the feedback from the 3.3 V and 5 V outputs for good cross-regulation. L2 3.3 H Operation The TOPSwitch-GX uses current mode feedback to achieve excellent no-load standby. Components C16, R1 and Q2 provide a constant current powering the TOPSwitch-GX CONTROL pin. Resistor R2 feeds the remainder of Q2 current to the M pin, reducing TOPSwitch-GX current limit with increased current. Resistor R11 sets the maximum current limit of the device. Components R6, Q1 and C13 implement slope compensation. C8 1 nF Y1 D1-D4 1N4005 F1 3.15 A 250 VAC 85 - 265 VAC C3 0.047 F x2 C1 33 F 400V VR1 P6KE180 C4 33 F 400V R7 100 C2 0.01 F 1 KV R5 47 D5 1N4007 D7 UF4003 12 V, 400 mA C20 150 F 25 V C15 470 F 25 V L3 3.3 H L4 3.3 H R9 200 U2B PC817 R8 1 k R16 6.34 k C17 470 F 10 V 5 V, 1.6 A C11 D11 1800 F 1N5822 25 V D10 1N5822 D8 UF4003 C12 1000 F 10 V C9 220 F 25 V C6 220 F 25 V R12 1 1/2 W PC817 U2A 3.3 V, 700 mA C18 470 F 10 V RTN R15 20 k C14 0.1 F R1 270 TOPSwitch-GX U1 TOP244P R2 20 k D M CONTROL C R10 3.3 k C16 0.33 F R6 20 k C7 10 F 50 V U3 TL431CLP R13 10 k Q2 2N3906 Q1 2N3906 - 12 V, 100 mA D9 C10 1N4148 47 F 50 V R11 7.5 k L1 1.4 H 0.5 A S C13 47 pF R14 6.8 C5 47 F 10 V C19 0.1 F PI-3321-111902 Figure 1. TOPSwitch-GX DVD Player Schematic. . DI-39 www.powerint.com November 2002 DI-39 Key Design Points * Use of foil for the 3.3 V and 5 V windings also helps to optimize cross-regulation. * Optional capacitor C7 is the "soft-finish" capacitor and prevents overshoot on startup. * Compact layout for components D7, D10, D11, C11, C12, C15 will improve cross-regulation and efficiency. Compact layout for L2, L3, L4, C17, C18, and C20 will achieve best output ripple. * Figure 2 shows conducted EMI at 230 VAC full load, with output "Artificial Hand" grounding. Floating output return gives lower results. * Table 2 shows the cross regulation of the supply over load for both 115 VAC and 230 VAC. PI-3408-112502 TRANSFORMER PARAMETERS Core Material Bobbin EEL25 Himag MZ4 EEL25.4, Taiwan AL of 344 nH/T2 EEL25 Vertical 14 Pins Shield: 32T x 2 x 32 AWG Primary: 64T x 2 x 32 AWG Bias: 10T x 4 x 32 AWG Shield: 2T x 8 x 32 AWG +3.3V: 4T x foil 0.052 x 14 mm +5V: 1T x foil 0.052 x 14 mm +12V: 4T x 4 x 32 AWG -12V: 7T x 4 x 32 AWG Shield (NC-5), tape, Primary (1-4), tape, Bias (7-6), tape, Shield (5-NC), tape, +12 V (13-8), +3.3 V (11,12-9,10), +5 V (9-10,13), tape, -12 V (14-11, 12), tape 1.42 mH 10% at 132 kHz Winding Details Winding Order (Pin Numbers) Primary Inductance (Pins 1-4 all others open) Primary Resonant Frequency Leakage Inductance 80 70 60 50 40 QP AV Quasi Peak 300 kHz minimum 30 H maximum dBV 30 20 10 0 -10 -20 0.15 1.0 10.0 -100.0 Average Table 1. Transformer Construction Information. MHz Output Voltage (V) 3.3 5 12 -12 Load Range (%) 10-100 10-100 10-100 100 Cross Regulation (%) -4 -3 -2 -1 0 1 2 3 4 Figure 2. EMI at 230 VAC Full Load with "Artificial Hand" Grounding of Output. Table 2. Worst Case Cross Regulation at 115 VAC and 230 VAC. 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. WORLD HEADQUARTERS AMERICAS Power Integrations, Inc. San Jose, CA 95138 USA Customer Service: Phone: +1 408-414-9665 Fax: +1 408-414-9765 e-mail: usasales@powerint.com CHINA Power Integrations International Holdings, Inc. China Phone: +86-755-8367-5143 Fax: +86-755-8377-9610 e-mail: chinasales@powerint.com A 11/02 EUROPE & AFRICA Power Integrations (Europe) Ltd. United Kingdom Phone: +44-1344-462-300 Fax: +44-1344-311-732 e-mail: eurosales@powerint.com KOREA Power Integrations International Holdings, Inc. Seoul, Korea Phone: +82-2-782-2840 Fax: +82-2-782-4427 e-mail: koreasales@powerint.com SINGAPORE Power Integrations, Singapore Republic of Singapore 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: singaporesales@powerint.com JAPAN Power Integrations, K.K. Keihin-Tatemono 1st Bldg. Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: japansales@powerint.com APPLICATIONS HOTLINE World Wide +1-408-414-9660 TAIWAN Power Integrations International Holdings, Inc. Taipei, Taiwan Phone: +886-2-2727-1221 Fax: +886-2-2727-1223 e-mail: taiwansales@powerint.com INDIA (Technical Support) Innovatech Bangalore, India Phone: +91-80-226-6023 Fax: +91-80-228-9727 e-mail: indiasales@powerint.com APPLICATIONS FAX World Wide +1-408-414-9760 www.powerint.com |
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