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Design Idea DI-30 ® TOPSwitch-GX
180 W PC Main SFX Supply
Application PC Main Device TOP249Y Power Output 180 W Input Voltage Output Voltage Topology Forward 90-130 VAC / 180-265 VAC 3.3 V / 5 V / 12 V / -12 V

®

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 (DCMAX) prevents transformer saturation for fault and transient loads · Uses conventional magamp for 3.3 V output · Meets CISPR22B/EN55022B conducted EMI

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 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.
C10 1 nF 50 V 5 R1 330 k C4 2.2 nF 1 kV D1 1N5407 2 R3 2.2 M R4 2.2 M R5 180 k 1 14 D7 MBR3045 13 R30 1 1W 8, 9, 10 R6 2.2 M C20 330 pF 50 V 11,12 3 R13 10 D8 MBR6045 C12 2200 µF 6.3 V R21 270 C9 47 nF 50 V 7, 8 Coupled choke L1 13 µH

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,

4 1, 2 C11 1000 µF 16 V L2 0.5 µH

+12 V

6

3

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

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

C2 470 µF 200 V

Q4 MPSA42

LPFC2 CY4 2.2 nF (Safety) Q6 MPSA92 To AC Selector Switch VR3 BZY97C200 VR4 BZY97C180 VR5 BZY97CR2 180 330 k
D L CONTROL C

TOPSwitch-GX U1 TOP249
R8 130 k 1% R36 43.2 k 1% C22 100 pF 50 V R7 560 k

D6 BAV20 D18 BAV20

4

C5 1 µF 100 V

C27 330 pF 50 V R11 330 D20 UF4002

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

VR19 1N5229

C3 470 µF 200 V

R20 270 k

S

X

F

C8 0.033 µF 50 V

R9 47 C6 47 µF 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-3384-120902

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. 180 W (200 W pk.) PC Main Power Supply Schematic (Note: Schematic does not include transformer Y-capacitor).
DI-30

www.powerint.com

December 2002

DI-30
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). 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 2mW by supplying external current to the CONTROL pin from the +15 V standby supply. Resistor R11 is required to allow external bias feed. clamp/reset circuit to maintain drain voltage < 600 V and DCMAX 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 Application 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) will be available for this design Dec. 2000. For updates and all other information please refer to Power Integrations' Web site.
L5 0.5 µH 3.3 V L3 Mag Amp 6 Turns Q2 TIP32 R34 33 D11 UF4002 RTN D10 UF4002 R22 3

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
D9 MBR2045 FROM MAIN CONVERTER 5 V WINDING L4 20 µH

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

R25 2.7 k

R24 3.84 k 1%

C14 1200 µF 10 V

C15 1200 µF 10 V

R26 10 k 1%

RTN
PI-3385-093002

Figure 2. Magamp for Independent 3.3 V Secondary Regulation.

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. ©Copyright 2002, Power Integrations, Inc.
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B 12/02

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