February 2006
www.powerint.com
PRODUCT HIGHLIGHTS
• Extended power range for higher power applications
• No heatsink required up to 34 W using P package
• Tight temperature and absolute tolerance on critical
parameters
• Integrates high-voltage power MOSFET, PWM control,
fault protection, and other control circuitry onto a
monolithic IC
• TO-220/262/263, DIP-8 & SMD-8 packages
TOPSwitch-GX Family
®
Extended Power, Design Flexible,
EcoSmart, Integrated Off-line Switcher IC
®
PI-2632-060200
AC
IN
DC
OUT
D
S
C
TOPSwitch-GX
CONTROL
L
+
-
FX
TYPICAL FLYBACK APPLICATION
LOW SYSTEM COST, HIGH DESIGN FLEXIBILITY
• Fully integrated soft-start for minimum stress/overshoot
• Externally programmable accurate current limit
• Wider duty cycle for more power, smaller input capacitor
• Separate line sense & current limit pins on Y/R/F packages
• Line under-voltage (UV) detection for no turn-off glitches
• Line overvoltage (OV) shutdown extends line surge limit
• Line feed-forward with maximum duty cycle (DCMAX) reduction
rejects ripple and limits DCMAX at high line
• 132 kHz frequency reduces transformer/power supply size
EcoSmart® - ENERGY EFFICIENCY
• Extremely low consumption in remote OFF mode
(80 mW @ 110 VAC, 160 mW @ 230 VAC)
• Frequency lowered with load for high
standby efficiency
• Allows shutdown/wake-up via
LAN/input port
FEATURES & BENEFITS
PRODUCT FAMILY
See Data Sheet for Additional Notes and Conditions
PACKAGE OPTIONS
TO-220 DIP-8 SMD-8 TO-263 TO-262
Y P G R F
FEBRUARY 2006 UPDATE
PRODUCT Adapter Open
Frame
Open
Frame
230 VAC ±15%
Adapter
85-265 VAC
Applications: Charger, DVD, Set-Top Box, PC Standby,
Broadband Modem, Notebook Adapter, LCD Monitor.
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2
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TOPSwitch-GX Family Design Tools
®
POWER SUPPLY DESIGN SOFTWARE
With PI Expert™, you’re only “mouse-clicks”
away from determining the key components
in your next switching power supply design,
including the best Power Integrations power
IC and design details for the transformer!
It’s fast & easy...and best of all, FREE!
DESIGN ACCELERATOR KITS
DAKs include a working prototype power supply,
sample devices, unpopulated pcb, data sheet, com-
prehensive engineering report & other related docu-
mentation.
DAK-12 145 W, PC Main Power Supply
DAK-31 180 W, PC Main Power Supply
DAK-32 20 W, Universal Input, DVD Supply, No Heatsink
DAK-33 45 W, 12 V LCD Power Supply
DAK-34 30 W, 12 V Universal Input Power Supply
TOPSwitch-GX PRODUCT & DESIGN COLLATERAL*
Data Sheet TOP242-250 TOPSwitch-GX Family Data Sheet
Application
Notes
AN-29 TOPSwitch-GX Flyback Quick Selection Curves
AN-30 TOPSwitch-GX Forward Design Methodology
AN-32 TOPSwitch-GX Flyback Design Methodology
Design Ideas
DI-12 Application: Lead Acid Battery Charger Design (16 W, Universal Input)
DI-16 Application: Set-top Box (57 W, 230 VAC Input)
DI-17 Application: PC Standby (17 W)
DI-20 Application: PC Main ATX (145 W)
DI-21 Application: LCD Monitor Adapter (45 W, Universal Input)
DI-22 Application: Laptop Adapter (70 W, 19 V, Universal Input)
DI-23 Application: High Speed Modem (10 W, Universal Input)
DI-26 Application: DVB-T (7 W, 230 VAC Input)
DI-30 Application: PC Main SFX (180 W)
DI-35 Application: Audio Amplifier w/ No Heatsink (16 W - 35 W Peak, Universal Input)
DI-39 Application: DVD (13 W, Universal Input)
DI-41 Application: Set-top Box (43 W, 100/115 VAC Input)
DI-43 Application: Medium Power AC-DC Power Supply (30 W, Universal Input)
DI-55 Application: DVD w/ No Heatsink (20 W, Universal Input)
DI-66 Application: LCD Monitor (45 W, 90 - 265 VAC Input)
DI-67 Application: LED Arrays (17.6 W, 108 - 132 VAC, 60 Hz Input)
* Downloadable from www.powerint.com
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3
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Application Device Power Output Input Voltage Output Voltage Topology
DVD TOP245P 20 W (25 W pk) 85-265 VAC 3.3 V / 5 V / 12 V / -24 V Flyback
Design Idea DI-55
TOPSwitch-GX
20 W (25 W peak) DVD Supply
Design Highlights
• Simple, low cost, low part count solution
• No heatsink required
• Low EMI-frequency jitter allows EN55022B/FCC B
compliance with simple EMI filter
• High efficiency, >75% at 90 VAC
• Low zero load power consumption, <100 mW at
230 VAC
• Low standby power consumption, <1 W input at 0.5 W output,
230 VAC
• Excellent cross-regulation
• Differential and common mode surge immunity to 3 kV
(EN 61000-4-5)
Operation
The TOP245P selected for the design in Figure 1 is ideal for DVD and
set-top applications. The P package removes the need for a heatsink
while still delivering 20 W/25 W peak at an ambient temperature of
50 °C.
The external current limit programming and remote ON/OFF
(inhibit) functions of the M pin allow current mode control and reduced
switching frequency at light and no-load conditions. Current mode
control is implemented by R2, Q3, R3, C16, R4 and R6.
Feedback current above ~2 mA (U1 supply current) forward biases
Q3 and pulls up R6. This adjusts the sink current out of the M pin,
Figure 1. 20 W Multiple Output DVD Supply.
PI-3648-080603
RV1
275 VAC C3
0.047 µF
X2
C1
33 µF
400 V
C8
2.2 nFY1
T1
EE25L
VR1
P6KE
130
C4
33 µF
400 V
D6
1N4148
D5
1N4007GP
R7
1 kΩ
R1
68 Ω
L1
5 mH
CM Choke
1N4007 x 4
F1
3.15 A
250 VAC
RT1
t°
+12 V, 500mA
OPTIONAL
+5 V, 2.5 A
J2-3
+3.3 V, 2 A
J2-6
RET
J2-2, 4, 5, 7
-24 V, 50 mA
J2-1
J1-2
LINE
J1-1
NTRL
U1
TOP245P
TOPSwitch-GX
D
S
C
CONTROL
M
Q3
1N3906
C13
47 µF
25 V
C5
47 µF
25 V
C14
0.1 µF
C9
150 µF
35 V
C6
150 µF
35 V
C12
1200 µF
10 V
C15
470 µF
25 V
C20
180 µF
25 V
L2
3.3 µH
L5
BEAD
L3
3.3 µH
L4
3.3 µH
C12
1200 µF
10 V
R17
200 Ω
D7
1N5819
1
4
8
12
13
9
10,11
14
7
5
D11
SB540CT
D10
SB540CT
R12
6.34 kΩ
1%
R11
20.0 kΩ
1%
C17
470 µF
10 V
D8
1N4005
Q1
2SA0885
D9
1N4005
R14
1.13 kΩ
1%
R16
2.0 kΩ
1%
R15
2.4 kΩ
R13
20.0 kΩ
1%
C18
470 µF
10 V
R8
1 Ω
1/2 W
D12
UF4003
R10
10 kΩ
U3
TL431
U2
R9
10.0 kΩ
1%
LTV817A
R4
10 kΩ
R2
18 kΩ
R3
270 Ω
C16
0.1 µF
C2
0.01 µF
1 kV
R6
5.1 kΩ
Q4
2N3904
Q5
2N3906
®
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DI-55
4
Table 1. Transformer Construction Information.
TRANSFORMER PARAMETERS
Core Material EEL25, N67 or equivalent,
gap for ALG of 202 nH/T2
Bobbin 7 pin + 7 pin
Winding Details
Shield 1: 32T, 2 x 32 AWG
Primary: 63T, 2 x 32 AWG
Bias: 6T, 4 x 32 AWG
Shield 2: 4T, 4 x 32 AWG
3.3 V/5 V foil: 2T + 1T, 0.12 mm foil
-24 V: 13T, 2 x 32 AWG
+12 V: 4T, 4 x 32 AWG
Winding Order
(Pin Numbers)
Shield (NC-1), tape, primary
(1-4), tape, bias (5-7),
tape, shield 2 (13-NC),
foil, (10,11-9-13), -24 V
(14-10,11), 12 V (12-8)
Inductance Primary: 800 µH ±10%
Leakage: 80 µH (max.)
Primary Resonant
Frequency 300 kHz (minimum)
thereby allowing the output voltage feedback loop to control the
primary switch current.
Resistor R6 sets the maximum current limit, while R2 and C16 provide
slope compensation. The value of R4 is chosen to ensure that current
does not flow into the M pin, enabling the line sensing features of the
pin. The current out of the M pin falls as the load is reduced until the
M pin inhibit threshold is reached. The supply then operates with a
fixed 25% current limit, lowering the switching frequency to maintain
regulation. This greatly reduces switching losses, maintaining high
standby efficiency and low no-load power consumption.
Key Design Points
• For good cross-regulation, minimize transformer leakage – use
foil for 3.3 V and 5 V outputs; minimize peak primary currents by
designing transformer for continuous conduction mode.
• Shunt regulator (temperature compensated) between 5 V and 3.3 V
outputs in dotted box on schematic is optional. It is only necessary
where min and max load conditions do not occur simultaneously
on both outputs.
• Feedback is taken from both the 3.3 V and 5 V outputs to the refer-
ence (U3) via R9, R11 and R12. The 12 V output is DC stacked on
the 5 V output for enhanced regulation and voltage centering.
• Primary clamp components VR1, D5, R7, R1 and C2 limit the
leakage inductance induced peak drain voltage spike.
• D5 is a slow recovery diode to recover some of the clamp energy.
It must be a glass passivated type to guarantee a defined trr.
• Use a Zener clamp for lowest zero load input power consumption.
Voltage
(V)
Load
Range
(A)
Regulation (%)
-5 -4 -3 -2 -1 0 1 2 3 4 5 6 7
3.3 0.3-0.6
5 0.3-1.2
12 0.1-0.2
-24 0.03-0.05
Table 2. Worst Case Output Cross-Regulation - All Outputs Taken
from Minimum to Maximum Loads.
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. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATIONS, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. The products and applications illustrated herein (transformer construction and circuits external to the
products) 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. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, EcoSmart, Clampless, E-Shield, Filterfuse, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other
trademarks are property of their respective companies. Copyright 2006, Power Integrations, Inc.
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