EEL25 CISPR22 EN55022B IEC1000-4-5 MUR120 UF5402 MBR1045 P6KE170 IN4005 UF4007

® TOPSwitch-FX Set-top Box (multiple output) POWER ® INTEGRATIONS, INC. Application Device Power Output Input Voltage

Design Idea DI-9 ® TOPSwitch-FX Set-top Box (multiple output) POWER ® INTEGRATIONS, INC. Application Device Power Output Input Voltage Output Voltage Topology Set-top Box TOP233Y 35 W 230 VAC 3.3 V / 5 V / 18 V / 30 V / -5 V Flyback Design Highlights · · · · · High efficiency (>77%) Good cross regulation with no linear regulators Can deliver 20 W with universal input voltage range 132 kHz allow smaller transformer size (EEL25 EEL25) Line under-voltage (UV) and power system surge protection (OV) · Meets CISPR22 CISPR22 B / EN55022B EN55022B · Surge requirements of IEC1000-4-5 IEC1000-4-5 (1.2/50 µs) to: · 6 kV differential mode / 4 kV common mode · Ring wave immunity (IEEE C62.41) to 4 kV · · · Key Design Points · · R1 (2 M, 1/2 W) sets UV at 100 VDC and OV at 450 VDC. A 1/2 W resistor is required to give a voltage rating 350 VDC. · OV shut-down protects against long duration line voltage surges (common in some countries). During shut-down the drain voltage does not exceed the DC input voltage (no · output reflected or leakage inductance spike voltages) allowing the AC rail to rise to 495 VAC (700 VDC BVDSS rating) without damaging the TOPSwitch-FX. The transformer turns ratio was optimized (including output diode forward drops) to minimize the output voltage error between the 3.3 V and 5 V outputs. Feedback is taken from both the 3.3 V and 5 V outputs to the reference (U3) via R9, R10 and R11. Other output voltages are set by the transformer turns ratio. The low power 5 V output is shunt regulated by R5 and Zener diode D13. Pre-load resistor R12 is required to maintain regulation of the 30 V output when lightly loaded. A soft-finish characteristic is provided by C17, eliminating output overshoot. Second stage LC post-filtering was used on the 3.3 V, 5 V and 18 V high power outputs for low output ripple (L2, L3, L4 and C10, C12, C14). Primary clamp components VR1 and D6 limit the leakage inductance induced peak drain voltage to a safe value. A lower value of VR1 (170 V) improves cross regulation by reducing secondary leakage inductance 4 D8 MUR120 MUR120 Total Secondary Turns -5 V: 4 T x 28 AWG 3.3 V: 3 T x 24 AWG x 2 5 V: 4 T x 24 AWG x 2 18 V: 13 T x 28 AWG 30 V: 22 T x 28 AWG 12 C7 100 µF 50 V C9 200 µF 25 V D9 UF5402 UF5402 C6 2.2 nF 7 D10 MBR1045 MBR1045 VR1 P6KE170 P6KE170 D1-D4 IN4005 IN4005 D6 UF4007 UF4007 10 C1 0.1 µF X1 D J1 N C15 330 µF D12 1N5819 1N5819 10 V 4 R1 2 M 1/2 W T1 RV1 275 V 14 mm M F 18 V @ 550 mA J2-2 R13 2.4 k 5 V @ 2.5 A J3-1 3.3 V @ 3 A J3-2 C14 100 µF 10 V J4-1 D13 1N5231 1N5231 R5 5.1 D7 1N4148 1N4148 R6 51 5 U2 LTV817 LTV817 J5-1 C16 100 µF 10 V -5 V @ 100 mA J5-2 R10 18.2 k R7 510 R9 9.53 k TOPSwitch-FX CONTROL TOP233Y U1 S 30 V @ 100 mA J2-1 J4-2 RTN C4 100 nF F1 3.15 A L C2 33 µF 400 V C12 100 µF 10 V L4 3.3 µH, 3A C13 1000 µF 25 V 9 2 3 L1 20 mH 0.8 A C11 1000 µF 25 V D11 BYW29E200 BYW29E200 C10 100 µF 25 V L3 3.3 µH, 3A 8 1 C8 1 µF 50 V L2 3.3 µH, 1A C18 R8 10 0.1 µF C R3 6.8 C5 47 µF C17 22 µF 25 V 230 VAC ±15% U3 TL431CLP TL431CLP R11 11 k PI-2642-061300 PI-2642-061300 Figure 1. TOPSwitch-FX 35 W Set-top box supply schematic DI-9 www.powerint.com July 2001 DI-9 spikes. This is only possible due to a low VOR of 116 V at the expense of slightly higher clamp dissipation. · Extended duty cycle range allows low value input capacitor (33 µF for 20 W universal input). · Jittering provides large EMI margins with simple EMI filtering. Transformer Parameters Winding Order Half primary (3-2), Bias (4-5), 3 layers tape, 30 V (11-12), 18 V (12-7), 1 layer tape, 5 V bifilar (7-9), 3.3 V bifilar (8-9), -5 V (9-10), 3 layers tape, Half primary (2-1), 1 layer tape 1100 µH ±10% 1.5 MHz (minimum) 12 µH (maximum) PI-2732-040901 PI-2732-040901 Yih Hwa YW-384 YW-384 or equivalent Leakage Inductance (pin 1-2, with pins 5-7 shorted) AV Bobbin Primary Resonant Frequency (pins 1-2, all others open) QP Nicera EEL25 EEL25.4 NC-2H or equiv. Gap for AL of 155 nH/T2 Primary Inductance (pins 1-3, all others open) CISPR22/EN55022B CISPR22/EN55022B Core Material QP AV Table 2. Transformer construction information Figure 2. Conducted EMI (230 VAC, 35 W) Pin Side 1 2 Tape 1/2 Primary Tape 10 3.3 V 5.1 V 18 V 30 V -5 V Min. 3.15 4.91 17.24 28.71 -4.93 Max. 3.36 5.34 19.01 30.76 -5.23 Spec. ±0.16 ±0.25 ±1.35 ±2.25 9 8 Secondary Tape 7 ±0.375 12 11 Table 1. Output cross regulation (all outputs from min to max load, 20 samples) Tape 5 4 2 3 Bias 1/2 Primary PI-2721-032201 PI-2721-032201 Figure 3. Transformer build diagram 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 PI Logo, TOPSwitch, TinySwitch and EcoSmart are registered trademarks of Power Integrations, Inc. ©Copyright 2001, Power Integrations, Inc. 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