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DI-146 Design Idea TOPSwitch-HX

®

35 W LCD Monitor Power Supply

Design Idea TOPSwitch-HX ® 35 W LCD Monitor Power Supply Application Device Power Output Input Voltage

Application

Device

Power Output

Input Voltage

Output Voltage

Topology

LCD Monitor

TOP258PN

35 W

90 – 264 VAC

5 V, 15 V

Flyback

Design Highlights

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

minimize cost by eliminating external heatsinks. Ideal applications 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 effi ciency 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

C7 C12 C6 2.2 nF R11 470 pF 3.9 nF 250 VAC 33 100 V
C7
C12
C6
2.2 nF
R11
470
pF
3.9 nF
250 VAC
33
100
V
1 kV
C13
C14
C15
D7
L2
T1
680 F
680 F
220
F
R6
SB580
3.3 H
EER28
25 V
25 V
25
V
22 k
2 W
2
7
+15 V,
1.9
A
VR1
C16
D1
D2
C18
R12
L3
P6KE170A
470
pF
1N4937
1N4007
220 F
RTN
33
3.3 H
100
V
10 V
3
11
+5 V,
1.7
A
D8
R7
SB530
10
4
9
1/2 W
RTN
C17
C10
6
2200 F
D3
10
F
D5
C11
10 V
1N4937
D4
R3
D6
R10
50
V
FR106
2.2 nF
1N4007
2.0 M
FR106
4.7
R19
250 VAC
5
10
L1
R4
6.8 mH
2.0 M
VR3
R14
BZX79-B10
22
C5
C4
R13
10 V
22 nF
100
F
330
2%
R1
R2
C19
630 V
400
V
VR2
1 M
1 M
R5
1N5250B
1.0 F
50 V
U2B
5.1 k
20 V
C3
PC817A
R15
220 nF
F1
1 k
275 VAC
3.15 A
U2A
TOPSwitch-HX
PC817A
RT1
D
M
t O
U1
L
R18
R20
10
TOP258PN
CONTROL
255k
12.4 k
C
1%
1%
E
R16
R17
10
k
10 k
N
R8
D9
S
6.8
1N4148
C8
90 - 265
VAC
C21
100 nF
C9
220
nF
50 V
47
F
50 V
16
V
C20
10
F
U3
R21
50
V
TL431
10 k
2%
1%

Figure 1.

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

www.powerint.com

PI-4797-011608

January 2008

PI-4798-090407

will also result in an increased voltage at the output of the bias 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 voltage is internally reduced by 0.5 V. If the M pin current exceeds 336 μA, the OV condition causes a latched shutdown. If the M pin current is between 112 μA and 336 μA for >100 μs, the shutdown is hysteretic. Resistor R5 defines the M pin current.

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

Key Design Points

Capacitor C5 is a decoupling capacitor connected across the DC supply and is located physically close to the high frequency switching circuit, which helps in reducing differential mode EMI.

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- tion, thereby maximizing efficiency at light load. Zener diode VR1 provides a defined maximum clamp voltage and typically only conducts during load transients or during an overload condition.

The secondary side snubber (R11, C12, R12 and C16) reduce high frequency secondary diode ringing and improve EMI.

In a three-wire system, placing Y capacitors between line/ neutral and earth ground helps reduce common mode EMI.

As the output return is connected to safety earth ground, two 2.2 nF Y capacitors (C7 and C11) are acceptable. For floating outputs, the maximum capacitance is normally limited to 1 x 2.2 nF due to line frequency leakage current limits.

Soft finish capacitor C20 ensures no output overshoot at start- up. Diode D9 isolates this capacitor from the feedback loop after start-up. Resistor R16 allows a path for this capacitor to discharge into the 5 V load.

80 70 QP 60 AV 50 40 30 20 10 0 -10 -20 dB V
80
70
QP
60
AV
50
40
30
20
10
0
-10
-20
dB V

0.15

Figure 2.

1.0

MHz

Worst Case Conducted EMI (230 VAC).

10.0

100.0

Transformer Parameters

Core Material

EER28 NC-2H or equivalent, gapped for ALG of 148 nH/t 2

Bobbin

EER28, 12 pin, Horizontal

Winding Details

3mm margins on both sides of bobbin to meet safety Primary: 20T × 1 AWG 26, tape Bias: 9T × 2, AWG 26, 3 layers, tape 5 V: 3T, foil 0.52 mm thickness

15

V: 5T × 3, AWG 26, 3 layers tape

Primary: 50T × 1, AWG 26, tape

Winding Order

Primary-1 (4-3), Bias (6-5), 5 V (11-9),

15

V (7-11), Primary-2 (3-2)

Primary Inductance

1041

μH, ±10%

Resonant

 

Frequency

 

1000

kHz (minimum)

Leakage

30

μH (maximum)

Inductance

Table 1.

Transformer Parameters. (NC = No Connection).

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