DI-146 Design Idea

®
TOPSwitch-HX

35 W LCD Monitor Power Supply

Application Device Power Output Input Voltage Output Voltage Topology

LCD Monitor TOP258PN 35 W 90 – 264 VAC 5 V, 15 V Flyback

Design Highlights minimize cost by eliminating external heatsinks. Ideal applications

• High efficiency
• >83% full load efficiency (Meets CEC 2008 requirements
of 82%)
• Delivers 35 W at 50° C ambient without requiring an external
heat sink
• Low no-load and standby power consumption
• 0.55 W standby output power for <1 W input
• No-load power consumption <160 mW at 230 VAC
• Integrated safety/reliability features:
• Accurate, auto-recovering, hysteretic thermal shutdown
function maintains safe IC temperatures under all conditions
• Auto-restart protects against output short circuits and open
feedback loops
• Output OVP configurable for latching or self recovering
• Meets EN55022 and CISPR-22 Class B conducted EMI with
>10 dBμV margin
Operation
The isolated flyback converter shown in Figure 1 was designed
around a member of the TOPSwitch-HX family, the TOP258PN
(U1). A device in the P package (8-pin DIP) was selected to
include LCD monitor power supplies, which typically require low
standby and no-load power consumption.
The AC input is rectified (D1–D4), filtered (C4) and connected
across the primary side power components (T1 and U1). Diodes
D1 and D3 were selected as fast recovery diodes for better EMI
performance. EMI filtering is provided by components, C4, C5,
L1, C7 and C11. Thermistor RT1 limits the inrush current drawn
by the circuit on application of input AC.
To optimize efficiency under all load conditions, U1 operates in
one of four modes. From no-load to full load, these are: multi-
cycle modulation, fixed frequency PWM (25 kHz), variable
frequency PWM and fixed frequency PWM (66 kHz). In all modes
the controller maintains a linear relationship between duty cycle
and control pin current so that the transition between modes is
seamless.
Zener diode VR2 and resistor R5 form the latching output over-
voltage protection (OVP) circuit. Increased voltage at the output

C6 C7 C12
3.9 nF 2.2 nF R11 470 pF
1 kV 250 VAC 33 7 100 V

D7 C13 C14 C15

R6 T1 SB580 680 MF 680 MF L2 220 MF
22 k7 2 EER28 7 25 V 25 V 3.3 MH 25 V +15 V,
2W 1.9 A
D1 D2 VR1 C16 C18
P6KE170A 470 pF R12 L3 RTN
1N4937 1N4007 33 7 3.3 MH 220 MF
100 V 10 V
3 11 +5 V,
1.7 A
R7 D8
10 7 SB530
4 9
1/2 W RTN
C10 C17
6 2200 MF
D3 10 MF
1N4937 D5 R10 50 V C11 10 V
D4 R3 D6
2.0 M7 FR106 FR106 4.7 7 2.2 nF R19
1N4007 250 VAC
5 10 7
L1 R4
6.8 mH 2.0 M7 VR3
R14 BZX79-B10
C5 C4 R13 22 7 10 V
R1 R2 22 nF 100 MF 330 7 C19 2%
1 M7 1 M7 630 V 400 V VR2 1.0 MF
R5 1N5250B 50 V
5.1 k7 20 V U2B
C3 PC817A R15
F1 220 nF 1 k7
3.15 A 275 VAC
U2A
TOPSwitch-HX PC817A
RT1 O D M U1
L 10 7 t R18 R20
CONTROL TOP258PN 255k7 12.4 k7
E C 1% 1%
R16 R17
10 k7 10 k7
N S R8 D9
C8 6.8 7 1N4148
90 - 265 C21
VAC 100 nF
50 V C9 220 nF
47 MF 50 V
16 V C20
10 MF U3 R21
50 V TL431 10 k7
2% 1%
PI-4797-011608

Figure 1. Universal input, 35 W Output, LCD Power Supply, Using a TOP258PN With No External Heat Sink.

www.powerint.com January 2008

will also result in an increased voltage at the output of the bias 80

PI-4798-090407
winding. Zener VR2 will break down, and current will flow into the
M pin of U1. When the M pin current exceeds 112 μA, the M pin 70
voltage is internally reduced by 0.5 V. If the M pin current exceeds QP
60
336 μA, the OV condition causes a latched shutdown. If the M AV
pin current is between 112 μA and 336 μA for >100 μs, the 50
shutdown is hysteretic. Resistor R5 defines the M pin current. 40

dBMV
Output voltage feedback is derived from both the outputs for 30
better cross-regulation. Capacitor C19 and resistor R14 form the 20
phase boost network and provide adequate phase margin to
ensure stable operation over the entire operating voltage range. 10
Resistors R19 and VR3 improve cross regulation when only the 0
5 V output is loaded, preventing the 15 V output operating at the
higher end of the specification. -10

Key Design Points -20

0.15 1.0 10.0 100.0
• Capacitor C5 is a decoupling capacitor connected across the
DC supply and is located physically close to the high frequency MHz
switching circuit, which helps in reducing differential mode EMI. Figure 2. Worst Case Conducted EMI (230 VAC).
• If latching OVP is desired, the value of R5 should be reduced to
20 Ω to allow for more current into the M pin.
• Design the RCD clamp (R6, R7, C6 and D5) for normal opera- Transformer Parameters
tion, thereby maximizing efficiency at light load. Zener diode EER28 NC-2H or equivalent, gapped for ALG of
VR1 provides a defined maximum clamp voltage and typically Core Material
148 nH/t2
only conducts during load transients or during an overload Bobbin EER28, 12 pin, Horizontal
condition.
3mm margins on both sides of bobbin to meet
• The secondary side snubber (R11, C12, R12 and C16) reduce
safety
high frequency secondary diode ringing and improve EMI. Primary: 20T × 1 AWG 26, tape
• In a three-wire system, placing Y capacitors between line/ Winding Details Bias: 9T × 2, AWG 26, 3 layers, tape
neutral and earth ground helps reduce common mode EMI. 5 V: 3T, foil 0.52 mm thickness
• As the output return is connected to safety earth ground, two 15 V: 5T × 3, AWG 26, 3 layers tape
2.2 nF Y capacitors (C7 and C11) are acceptable. For floating Primary: 50T × 1, AWG 26, tape
outputs, the maximum capacitance is normally limited to 1 x 2.2 Primary-1 (4-3), Bias (6-5), 5 V (11-9),
Winding Order
nF due to line frequency leakage current limits. 15 V (7-11), Primary-2 (3-2)
• Soft finish capacitor C20 ensures no output overshoot at start- Primary Inductance 1041 μH, ±10%
up. Diode D9 isolates this capacitor from the feedback loop Resonant
after start-up. Resistor R16 allows a path for this capacitor to 1000 kHz (minimum)
Frequency
discharge into the 5 V load.
Leakage
Inductance 30 μH (maximum)

Table 1. Transformer Parameters. (NC = No Connection).

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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.
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©2007, Power Integrations, Inc.

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01/08 DI-146