POWERINT DI-39

®
Design Idea DI-39
®
TOPSwitch-GX 13 W, Universal
Input DVD Supply with 70 mW No-load
Application
Device
Power Output
Input Voltage
DVD
TOP244P
13 W (17 W pk)
85-265 VAC
Design Highlights
•
•
•
•
•
•
•
Output Voltage
3.3 V / 5 V / 12 V / -12 V
Topology
Flyback
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.
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
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.
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.
Resistors R15 and R16 share the feedback from the 3.3 V
and 5 V outputs for good cross-regulation.
C8
1 nF
Y1
L2
3.3 µH
D1-D4
1N4005
F1
3.15 A
250 VAC
85 - 265
VAC
C3
0.047 µF
x2
VR1
P6KE180
C1
33 µF
400V
R7
100 Ω
C4
33 µF
400V
C15
470 µF
25 V
D7
UF4003
C11
D11
1800 µF
1N5822
25 V
C2
0.01 µF
1 KV
D10
1N5822
R5
47 Ω
D8
UF4003
D5
1N4007
L4
3.3 µH
C12
1000 µF
10 V
C9
220 µF
25 V
C6
220 µF
25 V
R8
1 kΩ
C14
0.1 µF
D
Q2
2N3906
M
C13
47 pF
CONTROL
C
R11
7.5 kΩ
L1
1.4 µH
0.5 A
S
C19
0.1 µF
R14
6.8 Ω
C5
47 µF
10 V
R6
20 kΩ
C18
470 µF
10 V
RTN
U2B
PC817
PC817
U2A
C16
0.33 µF
5 V, 1.6 A
3.3 V, 700 mA
C17
470 µF
10 V
R9
200 Ω
R12
1 1/2 W
R1
270 Ω
TOPSwitch-GX
U1
TOP244P
R2
20 kΩ
12 V, 400 mA
C20
150 µF
25 V
L3
3.3 µH
C7
10 µF
50 V
U3
TL431CLP
R16
6.34 kΩ
R15
20 kΩ
R10
3.3 kΩ
R13
10 kΩ
Q1
2N3906
- 12 V, 100 mA
D9
C10 1N4148
47 µF
50 V
PI-3321-111902
Figure 1. TOPSwitch-GX DVD Player Schematic.
.
DI-39
www.powerint.com
November 2002
DI-39
Key Design Points
TRANSFORMER PARAMETERS
• 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
80
70
60
QP
50
AV
dBµV
Bobbin
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
Winding Details
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
Winding Order
(Pin Numbers)
Primary Inductance
(Pins 1-4 all others
open)
Primary Resonant
Frequency
Quasi Peak
40
EEL25
Himag MZ4 EEL25.4, Taiwan AL of
344 nH/T2
Core Material
Leakage Inductance
30
1.42 mH ±10% at 132 kHz
300 kHz minimum
30 µH maximum
Table 1. Transformer Construction Information.
20
10
0
Average
-10
-20
0.15
1.0
10.0
-100.0
MHz
Figure 2. EMI at 230 VAC Full Load with "Artificial Hand"
Grounding of Output.
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
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. ©Copyright 2002, Power Integrations, Inc.
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11/02
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