Power Integrations RDR-142 Technical data

Title

Reference Design Report for a 35 W Power
Supply Using TOP258PN

90 VAC to 265 VAC Input

Specification

5 V, 2.2 A and 12 V, 2 A Output

Application
Author

LCD Monitor

Power Integrations Applications Department

Document

RDR-142

Number
Date
Revision

Summary and Features

• Low cost, low component count, high efficiency

• Delivers 35 W at 50°C ambient without requiring an external heat sink

• Meets output cross regulation requirements without linear regulators

• EcoSmart® – meets requirements for low no-load and standby power

consumption

• 0.42 W output power for <1 W input

• No-load power consumption < 300 mW at 230 VAC

• >82% full load efficiency

• Integrated safety/reliability features:

• Accurate, auto-recovering, hysteretic thermal shutdown function maintains

safe PCB temperatures under all conditions

• Auto-restart protects against output short circuits and open feedback loops

• Output OVP protection configurable for latching or self recovering

• Input UV prevents power up / power down output glitches

• Meets EN55022 and CISPR-22 Class B conducted EMI with > 10 dBµV margin

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.

September 24, 2007

1.0

Power Integrations

5245 Hellyer Avenue, San Jose, CA 95138 USA.

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

Table of Contents

1 Introduction................................................................................................................. 4

2 Power Supply Specification ........................................................................................ 5

3 Schematic...................................................................................................................6

4 Circuit Description ......................................................................................................7

4.1 Input EMI Filtering ...............................................................................................7

4.2 TOPSwitch-HX Primary.......................................................................................7

4.3 Output Rectification .............................................................................................8

4.4 Output Feedback.................................................................................................9

4.5 PCB Layout ....................................................................................................... 10

5 Bill of Materials ......................................................................................................... 11

6 Transformer Specification......................................................................................... 13

6.1 Electrical Diagram .............................................................................................13

6.2 Electrical Specifications..................................................................................... 13

6.3 Materials............................................................................................................13

6.4 Transformer Build Diagram ...............................................................................14

6.5 Transformer Construction.................................................................................. 15

7 Design Spreadsheet .................................................................................................16

8 Performance Data ....................................................................................................20

8.1 Efficiency ...........................................................................................................20

8.1.1 Active Mode CEC Measurement Data........................................................20

8.2 No-load Input Power.......................................................................................... 22

8.3 Available Standby Output Power.......................................................................23

9 Regulation ................................................................................................................24

9.1.1 Load ...........................................................................................................24

9.1.2 Line ............................................................................................................25

9.1.3 Cross Regulation Matrix .............................................................................26

10 Thermal Performance ...........................................................................................27

11 Waveforms............................................................................................................ 28

11.1 Drain Voltage and Current, Normal Operation...................................................28

11.2 Output Voltage Start-up Profile..........................................................................28

11.3 Drain Voltage and Current Start-up Profile ........................................................ 30

11.4 Load Transient Response (75% to 100% Load Step) .......................................31

11.5 Output Over-voltage Protection ......................................................................... 32

11.6 Output Ripple Measurements ............................................................................33

11.6.1 Ripple Measurement Technique ................................................................33

11.6.2 Measurement Results ................................................................................34

12 Line Surge.............................................................................................................35

13 Control Loop Measurements.................................................................................36

13.1 90 VAC Maximum Load..................................................................................... 36

13.2 265 VAC Maximum Load................................................................................... 36

14 Conducted EMI .....................................................................................................37

15 Revision History ....................................................................................................38

Important Note:

Page 2 of 40

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24-Sep-07 RDR-142 35 W, TOP258PN Dual Output Supply

Although this board is designed to satisfy safety isolation requirements, the engineering
prototype has not been agency approved. Therefore, all testing should be performed
using an isolation transformer to provide the AC input to the prototype board.

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

1 Introduction

This document is an engineering report describing a LCD Monitor power supply utilizing a
TOP258PN. This power supply is intended as a general purpose evaluation platform for

TOPSwitch-HX.

The document contains the power supply specification, schematic, bill of materials,
transformer documentation, printed circuit layout, and performance data.

Figure 1 – Populated Circuit Board Photograph (5”L x 2.84”W x 1.16”H)

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24-Sep-07 RDR-142 35 W, TOP258PN Dual Output Supply

2 Power Supply Specification

Description Symbol Min Typ Max Units Comment

Input

Voltage
Frequency
No-load Input Power (230 VAC) 0.3 W

Output

Output Voltage 1
Output Ripple Voltage 1
Output Current 1

Output Voltage 2

Output Ripple Voltage 2
Output Current 2

Total Output Power

Continuous Output Power

Efficiency

Full Load

Standby Input Power 1 W

Required average efficiency at
25, 50, 75 and 100 % of P

OUT

Environmental

Conducted EMI

Safety

Surge

Differential
Common Mode

Surge

Ring Wave

Ambient Temperature

*Shown for information only as CEC requirement does not apply to internal power supplies

V

f

LINE

IN

90 265 VAC
47 50/60 64 Hz

3 wire input

V

OUT1

V

RIPPLE1

I

OUT1

V

OUT2

V

RIPPLE2

I

OUT2

4.75 5 5.25 V
100 mV

0 2.2 A

9.6 12 14.4 V

500 mV

0 2 A

± 5%

20 MHz bandwidth

± 20%

20 MHz bandwidth

P

OUT

35 W

Measured at P

5 V @ 82 mA, 12 V @ 0 mA;

Vin at 264 VAC

Per California Energy Commission

(CEC) / Energy Star requirements

η

η

CEC

82 %

*

81

%

Meets CISPR22B / EN55022B

Designed to meet IEC950, UL1950

1
2

1 kV

0 50

T

AMB

Class II

1.2/50 µs surge, IEC 1000-4-5,

kV
kV

o

C

Series Impedance:
Differential Mode: 2 Ω
Common Mode: 12 Ω

100 kHz ring wave, 500 A short

circuit current, differential and

common mode

Free convection, sea level

OUT

25

o

C

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

3 Schematic

*

Figure 2 – Schematic.

Optional for 2 wire input, floating output

*

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4 Circuit Description

A Flyback converter configuration built around TOP258PN is used in this power supply to
obtain two output voltages. The 5 V output can supply a load current of 2.2 A, and the 12
V output can supply a load current of 2.0 A. This power supply can operate between 90
– 264 VAC. The 5 V output is the main regulated output. This output is regulated using a
TL431 voltage reference. Some feedback is also derived from the 12 V output for
improved cross regulation.

4.1 Input EMI Filtering

The three wire AC supply is connected to the circuit using connector J1. Fuse F1
provides protection against circuit faults and effectively isolates the circuit from the AC
supply source. Thermistor RT1 limits the inrush current drawn by the circuit at start up.
Optional capacitors C1 and C2 are Y capacitors connected from the Line/Neutral to Earth
to reduce common mode EMI.

Capacitor C3 is the X capacitor and helps to reduce the differential mode EMI. Resistors
R1 and R2 discharge C3 on AC removal, preventing potential user shock. Inductor L1 is
a common-mode inductor and helps in filtering common-mode EMI from coupling back to
the AC source.

Diodes D1, D2, D3 and D4 form a bridge rectifier. The bridge rectifier rectifies the
incoming AC supply to DC, which is filtered by capacitor C4.

Diodes D1 and D3 are fast recovery type diodes. These diodes recover very quickly
when the voltage across them reverses. This reduces excitation of stray line inductance
in the AC input by reducing the subsequent high frequency turnoff snap and hence EMI.
Only 2 of the 4 diodes in the bridge need to be fast recovery type, since 2 diodes conduct
in each half cycle.

4.2 TOPSwitch-HX Primary

Resistor R3 and R4 provide line voltage sensing and provide a current to U1, which is
proportional to the DC voltage across capacitor C4. At approximately 95 V DC, the
current through these resistors exceeds the line under-voltage threshold of 25 µA, which
results in enabling of U1.

The TOPSwitch-HX regulates the output using PWM-based voltage mode control. At
high loads the controller operates at full switching frequency (66 kHz for P package
devices). The duty cycle is controlled based on the control pin current to regulate the
output voltage.

The internal current limit provides cycle-by-cycle peak current limit protection. The
TOPSwitch-HX controller has a second current limit comparator allowing monitoring the
actual peak drain current (IP) relative to the programmed current limit I

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LIMITEXT

. As soon

RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

as the ratio IP/I

LIMITEXT

falls below 55%, the peak drain current is held constant. The
output is then regulated by modulating the switching frequency (variable frequency PWM
control). As the load decreases further, the switching frequency decreases linearly from
full frequency down to 30 kHz.

Once the switching frequency has reached 30 kHz the controller keeps this switching
frequency constant and the peak current is reduced to regulate the output (fixed
frequency, direct duty cycle PWM control).

As the load is further reduced and the ratio IP/I

LIMITEXT

falls below 25%, the controller will
enter a multi-cycle-modulation mode for excellent efficiency at light load or standby
operation and low no-load input power consumption.

Diode D5, together with R6, R7, C6 and Zener VR1, forms a clamp network that limits the
drain voltage of U1 at the instant of turn-off. Zener VR1 provides a defined maximum
clamp voltage and typically only conducts during fault conditions such as overload. This
allows the RCD clamp (R6, C6 and D5) to be sized for normal operation, thereby
maximizing efficiency at light load. Resistor R7 is required due to the choice of a fast
recovery diode for D5. A fast versus ultra fast recovery diode allows some recovery of
the clamp energy but requires R7 to limit reverse diode current and dampen high
frequency ringing.

The output of the bias winding is rectified by diode D6 and filtered by resistor R10 and
capacitor C10. This rectified and filtered output is used by the optocoupler U2 to provide
the control current to the control terminal of U1.

Should the feedback circuit fail (open loop condition), the output of the power supply will
exceed the regulation limits. This increased voltage at output 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 IC U1, thus initiating a hysteretic OVP shutdown with
automatic restart attempts. Resistor R5 limits the current into the M pin; if latching OVP
is desired, the value of R5 can be reduced to 20 Ω.

The output voltage of the power supply is maintained in regulation by the feedback circuit
on the secondary side of the circuit. The feedback circuit controls the output voltage by
changing the optocoupler current. Change in the optocoupler diode current results in a
change of current into the control pin of IC U1. Variation of this current results in
variation of duty cycle and hence the output voltage of the power supply.

4.3 Output Rectification

Output rectification for the 5 V output is provided by diode D8. Low ESR capacitor C17
provides filtering. Inductor L3 and capacitor C18 form a second stage filter that
significantly attenuates the switching ripple across C17 and ensures a low ripple output.

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24-Sep-07 RDR-142 35 W, TOP258PN Dual Output Supply

Output rectification for the 12 V output is provided by diode D7. Low ESR capacitors C13
and C14 provide filtering. Inductor L2 and capacitor C15 form a second stage filter that
significantly attenuates the switching ripple and ensures low ripple at the output.

Snubber networks comprising R11, C12 and R12, and C16 damp high frequency ringing
across diodes D7 and D8, which results from leakage inductance of the transformer
windings and the secondary trace inductances.

4.4 Output Feedback

Output voltage is controlled using the shunt regulator TL431 (U3). Diode D9, capacitor
C20 and resistor R16 form the soft finish circuit. At start-up, capacitor C20 is discharged.
As the output voltage starts rising, current flows into the optocoupler diode (U2A) via
resistor R13 and diode D9. This provides feedback to the circuit on the primary side.
The current in the optocoupler diode U2A gradually decreases as capacitor C20 charges
and U3 becomes operational. This ensures that the output voltage increases gradually
and settles to the final value without any overshoot. Resistor R16 provides a discharge
path for C20 into the load at power down. Diode D9 isolates C20 from the feedback
circuit after startup.

Resistor R18, R20 and R21 form a voltage divider network that senses the output voltage
from both the outputs for better cross-regulation. Resistor R19 and Zener VR3 improve
cross regulation when only the 5 V output is loaded, which results in the 12 V output
operating at the higher end of the specification.

Resistors R13, R17 and capacitor C21 set the frequency response of the feedback
circuit. Capacitor C19 and resistor R14 form the phase boost network that provides
adequate phase margin to ensure stable operation over the entire operating voltage
range.

Resistor R15 provides the bias current required by the IC U3 and is placed in parallel with
U2A to ensure that the bias current to the IC does not become a part of the feedback
current. Resistor R13 sets the overall DC loop gain and limits the current through U2A
during transient conditions.

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

4.5 PCB Layout

Figure 3 – Printed Circuit Layout.

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5 Bill of Materials

Item Qty

1 2
2 1 C3 220 nF, 275 VAC, Film, X2 Panasonic ECQ-U2A224ML

3 1 C4
4 1 C6 3.9 nF, 1 kV, Disc Ceramic, Y5P Panasonic ECK-A3A392KBP

5 2
6 1 C8 100 nF, 50 V, Ceramic, Z5U Kemet C317C104M5U5TA

7 1 C9

8 2

9 2

10 2

11 1 C15

12 1 C17

13 1 C18
14 1 C19 1.0 uF, 50 V, Ceramic, X7R Epcos B37984M5105K000
15 1 C21 220 nF, 50 V, Ceramic, X7R Epcos B37987F5224K000

16 2

17 2

18 2
19 1 D7 60 V, 5 A, Schottky, DO-201AD Vishay SB560
20 1 D8 30 V, 5 A, Schottky, DO-201AD Fairchild SB530
21 1 D9 75 V, 300 mA, Fast Switching, DO-35 Vishay 1N4148
22 1 F1 3.15 A, 250V,Fast, TR5 Wickman 37013150410
23 1 J1 5 Position (1 x 5) header, 0.156 pitch Molex 26-48-1055
24 2 J2 J3 2 Position (1 x 2) header, 0.156 pitch Molex 26-48-1025

25 1 JP1

26 1 JP2

27 1 JP3
28 1 L1 6.8 mH, 0.8 A, Common Mode Choke Panasonic ELF15N008
29 2 L2 L3 3.3 uH, 5.0 A Coilcraft RFB0807-3R3L

30 2

31 2

Ref
Des

C11 2.2 nF, Ceramic, Y1 Vishay 440LD22-R

C10
C20
C12
C16 470 pF, 100 V, Ceramic, COG AVX Corp 5NK471KOBAM
C13
C14

Description Mfg Mfg Part Number

C1
C2

1 nF, Ceramic, Y1 Panasonic ECK-ANA102MB

100 uF, 400 V, Electrolytic, Low ESR,
630 mOhm, (16 x 40)

C7

47 uF, 16 V, Electrolytic, Gen Purpose,
(5 x 11.5) Panasonic ECA-1CHG470
10 uF, 50 V, Electrolytic, Gen Purpose,
(5 x 11)

680 uF, 25 V, Electrolytic, Very Low
ESR, 23 mOhm, (10 x 20)
220 uF, 25 V, Electrolytic, Low ESR,
120 mOhm, (8 x 12)
2200 uF, 10 V, Electrolytic, Very Low
ESR,21 mOhm, (12.5 x 20)
220 uF, 10 V, Electrolytic, Low ESR,
250 mOhm, (6.3 x 11.5)

D1

600 V, 1 A, Fast Recovery Diode,

D3

200 ns, DO-41
D2
D4 1000 V, 1 A, Rectifier, DO-41 Vishay 1N4007
D5

800 V, 1 A, Fast Recovery Diode,
D6

500 ns, DO-41 Diodes Inc. FR106

Wire Jumper, Non insulated,

22 AWG, 0.4 in

Wire Jumper, Non insulated,

22 AWG, 0.8 in Alpha 298

Wire Jumper, Non insulated,

22 AWG, 0.3 in Alpha 298

R1
R2 1 M, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-1M0
R3
R4 2.0 M, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-2M0

Nippon Chemi­Con

Panasonic ECA-1HHG100

Nippon Chemi­Con EKZE250ELL681MJ20S
Nippon Chemi­Con
Nippon Chemi­Con EKZE100ELL222MK20S
Nippon Chemi­Con ELXZ100ELL221MFB5D

On
Semiconductor 1N4937RLG

Alpha 298

EKMX401ELL101ML40
S

ELXZ250ELL221MH12D

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

32 1 R5 5.1 k, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-5K1
33 1 R6 22 k, 5%, 2 W, Metal Oxide Yageo RSF200JB-22K
34 1 R7 20 R, 5%, 1/2 W, Carbon Film Yageo CFR-50JB-20R
35 1 R8 6.8 R, 5%, 1/8 W, Carbon Film Yageo CFR-12JB-6R8
36 1 R9 100 R, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-100R
37 1 R10 4.7 R, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-4R7

R11
38 2
39 1 R13 330 R, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-330R
40 1 R14 22 R, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-22R
41 1 R15 1 k, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-1K0

42 2
43 1 R18 196 k, 1%, 1/4 W, Metal Film Yageo MFR-25FBF-196K
44 1 R19 10 R, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-10R
45 1 R20 12.4 k, 1%, 1/4 W, Metal Film Yageo MFR-25FBF-12K4
46 1 R21 10 k, 1%, 1/4 W, Metal Film Panasonic ERO-S2PHF1002
47 1 RT1 NTC Thermistor, 10 Ohms, 1.7 A Thermometrics CL-120

48 1 T1

49 1 U1 TOPSwitch-HX, TOP258PN, DIP-8B

50 1 U2

51 1 U3

52 1 VR1
53 1 VR2 20 V, 5%, 500 mW, DO-35 Microsemi 1N5250B
54 1 VR3 8.2 V, 500 mW, 2%, DO-35 Vishay BZX55B8V2

R12 33 R, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-33R

R16

R17 10 k, 5%, 1/4 W, Carbon Film Yageo CFR-25JB-10K

Core
Bobbin: EER28, Horiz., 12 pins (6/6),

Complete Assembly (custom)

Opto coupler, 80 V, CTR 80-160%, 4­DIP NEC PS2501-1-H-A

2.495 V Shunt Regulator IC, 2%, 0 to
70C, TO-92
200 V, 600 W, 5%, TVS, DO204AC
(DO-15)

TDK
Ying-Chin

Ice Components
Magtel
Precision Inc.
Power
Integrations

On
Semiconductor TL431CLPG

OnSemi P6KE200ARLG

PC40EER28-Z
YC-2806-5

TOP07074
32/07 TR.RDK-142
019-4967-00R

TOP258PN

Note – Parts listed above are RoHS compliant

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6 Transformer Specification

6.1 Electrical Diagram

Figure 4 – Transformer Electrical Diagram.

6.2 Electrical Specifications

Electrical Strength

Primary Inductance

Resonant Frequency

Primary Leakage Inductance

1 second, 60 Hz, from Pins 2,3,4,5,6 to Pins 7,9,11 3000 VAC
Pins 2-4, all other windings open, measured at 100
kHz, 0.4 VRMS
Pins 2-4, all other windings open 1000 kHz (Min.)
Pins 2-4, with Pins 7-9 shorted, measured at
100 kHz, 0.4 VRMS

1040 µH, ±10%

20 µH (Max.)

6.3 Materials

Item Description

[1] Core: EER28 gapped for ALG of 213 nH/T
[2] Bobbin: EER28, Horizontal 12 pins (6/6), YC-2806-5
[3] Magnet Wire: #27 AWG, double coated.
[4] Magnet Wire: #26 AWG, double coated.
[5] Tape: 3M Polyester Film, 2.0 mils thick, 16.0 mm wide.
[6] Tape: 3M Polyester Film, 2.0 mils thick, 10.0 mm wide.
[7] Copper Foil, 2 mils thick, 142mm long, 8.5mm wide. To be wrapped over with tape item [6].
[8] Tape: 3M Polyester Film, 2.0 mils thick, 13.5 mm wide.

[9] Bare Wire: #22 AWG
[10] Tape: 3M Polyester Film, 2.0 mils thick, 8.0 mm wide.
[11] Varnish.

2

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

6.4 Transformer Build Diagram

2
3

11

7

9

11

5

6

3
4

2 x #28AWG connected to pin 7

( 3.1 mm pre-molded margin bobbin)

Bobbin: EER28 (Horizontal, 12pins, 6/6), YC-2806-5)
Lp(2-4):

1.04mH +/- 5%

Copper Fo il – 2mil thick

142mm

Figure 5 – Transformer Build Diagram.

margin tape

Tape: 3M Polyester Film – 2mil thick

2 x #28AWG connected to pin 11

8.5mm

13.5mm

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6.5 Transformer Construction

General Note

Primary side of the bobbin orients to the left hand side. Place 3.1 mm margin tape
on both sides for all windings except WD1 due to built-in 3.1 mm margin of bobbin.
Winding direction is clockwise.

1/2 Primary

Insulation

Insulation

st

Secondary

1

Insulation

nd

2

Secondary

Insulation

2/2 Primary

Insulation
Assembly

WD1

WD2
Bias

WD3

WD4

WD5

Finish

Start on pin 4, wind 24 turns of item [3] from left to right with tight tension and bring
the wire across the bobbin to terminate at pin 3.
2 layers of tape item [5].
Start on pin 6, wind 7 turns bifilar of item [4] from left to right, spread the winding
evenly, and bring the wire across the bobbin to terminate on pin 5.
2 layers of tape item [5].
Start on pin 11, wind 3 turns of item [7] and terminate at pin 9.

1 layer of tape item [5].
Start on pin 7, wind 4 turns quadfilar of item [4] from right to left, spread the winding
evenly across the bobbin, and bring the wire back to the right to terminate on pin11.
2 layers of tape item [5].
Start on pin 3, wind 23 turns of item [3] from left to right with tight tension, place 1
layer tape item [6], then wind another 23 turns of item [3] from right to left, also with
tight tension, and terminate at pin 2.
3 layers of tape item [5].
Grind the cores to get 1038 µH with ALG of 213 nH/T
Secure the cores by wrapping around 2 halves of cores with item [10]. Dip varnish

uniformly in item [11]

.

2

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

7 Design Spreadsheet

ACDC_TOPSwitchHX_09
0607; Rev.1.2; Copyright
Power Integrations 2007

ENTER APPLICATION VARIABLES RD-142

VACMIN 90 Volts Minimum AC Input Voltage
VACMAX 265 Volts Maximum AC Input Voltage
fL 50 Hertz AC Mains Frequency
VO 5.00
PO_AVG 35.00
PO_PEAK 35.00 Watts Peak Output Power
n 0.80 %/100 Efficiency Estimate
Z 0.50 Loss Allocation Factor
VB 12
tC 3.00 mSeco

CIN 100.0 100 uFara

ENTER TOPSWITCH-HX VARIABLES

TOPSwitch-HX TOP258PN Univer

Chosen Device

KI 1.00
ILIMITMIN_EXT 1.534 Amps Use 1% resistor in setting external ILIMIT

ILIMITMAX_EXT 1.766 Amps Use 1% resistor in setting external ILIMIT
Frequency (F)=132kHz,
(H)=66kHz

fS

fSmin
fSmax
High Line Operating Mode FF
VOR 128.00 Volts Reflected Output Voltage
VDS 5.63 5.63 Volts TOPSwitch on-state Drain to Source Voltage
VD 0.50 Volts Output Winding Diode Forward Voltage Drop
VDB 0.70 Volts Bias Winding Diode Forward Voltage Drop
KP 0.69

INPUT INFO

Info

TOP258PN

H

66000 Hertz TOPSwitch-HX Switching Frequency: Choose

OUTPU
T

Volts Output Voltage (main)
Watts Average Output Power

Volts Ensure proper operation at no load.

Power
Out

H Only half frequency option available for P, G

59400 Hertz TOPSwitch-HX Minimum Switching Frequency
72600 Hertz TOPSwitch-HX Maximum Switching Frequency

Ripple to Peak Current Ratio (0.3 < KRP < 1.0

UNIT

nds

ds

sal /
Peak
35 W /
50 W

External Ilimit reduction factor (KI=1.0 for

TOPSwitch_HX_090607: TOPSwitch-HX
Continuous/Discontinuous Flyback
Transformer Design Spreadsheet

Bridge Rectifier Conduction Time Estimate

Input Filter Capacitor

115 Doubled/230V
48W

default ILIMIT, KI <1.0 for lower ILIMIT)

and M package devices. For full frequency
operation choose Y package.

between 132 kHz and 66 kHz

: 1.0< KDP<6.0)

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24-Sep-07 RDR-142 35 W, TOP258PN Dual Output Supply

PROTECTION FEATURES

LINE SENSING Note - For P/G package devices only one of

VUV_STARTUP 95.00 95 Volts DC Bus Voltage at which the power supply will

VOV_SHUTDOWN 445 Volts DC Bus Voltage at which power supply will

RLS 4.0 M­OUTPUT OVERVOLTAGE

VZ 22 Volts Zener Diode rated voltage for Output

RZ 5.1 k­OVERLOAD POWER LIMITING

Overload Current Ratio at VMAX 1.2 Enter the desired margin to current limit at

Overload Current Ratio at VMIN
ILIMIT_EXT_VMIN 1.23 A External Current limit at VMIN
ILIMIT_EXT_VMAX 1.14 A External Current limit at VMAX
RIL 8.29 k-

RPL 29.27 M-

ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES

Core Type EER28 EER28 Core Type

Core
Bobbin

AE 0.821 cm^2 Core Effective Cross Sectional Area
LE 6.4 cm Core Effective Path Length
AL 2870 nH/T^2 Ungapped Core Effective Inductance

EER28_BO

EER28

1.25 Margin to current limit at low line.

BBIN

ohms

ohms

ohms

ohms

P/N:
P/N:

either Line sensing or Overload power limiting
protection featues can be used. For all other
packages both these functions can be
simultaneously used.

start-up

shut-down
Use two standard, 2 M-Ohm, 5% resistors in
series for line sense functionality.

Overvoltage shutdown protection
Output OVP resistor. For latching shutdown
use 20 ohm resistor instead

VMAX. A value of 1.2 indicates that the current
limit should be 20% higher than peak primary
current at VMAX

Current limit/Power Limiting resistor.

Power Limiting resistor

PC40EER28-Z

BW 16.7 mm Bobbin Physical Winding Width
M 3.00 mm Safety Margin Width (Half the Primary to

L 3.00 Number of Primary Layers
NS 3 3 Number of Secondary Turns

DC INPUT VOLTAGE PARAMETERS

VMIN 100 Volts Minimum DC Input Voltage
VMAX 375 Volts Maximum DC Input Voltage

CURRENT WAVEFORM SHAPE PARAMETERS

DMAX
IAVG 0.44 Amps Average Primary Current (calculated at

IP 1.16 Amps Peak Primary Current (calculated at Peak

IR 0.80 Amps Primary Ripple Current (calculated at average

IRMS 0.60 Amps Primary RMS Current (calculated at average

0.57 Maximum Duty Cycle (calculated at PO_PEAK)

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Page 17 of 40

Secondary Creepage Distance)

average output power)

output power)

output power)

output power)

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TRANSFORMER PRIMARY DESIGN PARAMETERS

LP 1040 uHenries Primary Inductance
LP Tolerance 10 Tolerance of Primary Inductance
NP 70 Primary Winding Number of Turns
NB 7 Bias Winding Number of Turns
ALG 213 nH/T^2 Gapped Core Effective Inductance
BM 2101 Gauss Maximum Flux Density at PO, VMIN

BP 3524 Gauss Peak Flux Density (BP<4200) at ILIMITMAX

BAC 725 Gauss AC Flux Density for Core Loss Curves (0.5 X

ur 1780 Relative Permeability of Ungapped Core
LG
BWE 32.1 mm Effective Bobbin Width
OD 0.46 mm Maximum Primary Wire Diameter including

INS 0.06 mm Estimated Total Insulation Thickness (= 2 * film

DIA 0.40 mm Bare conductor diameter
AWG 27 AWG Primary Wire Gauge (Rounded to next smaller

CM 203 Cmils Bare conductor effective area in circular mils
CMA

Primary Current Density (J) 5.88 Amps/m

TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT)

Lumped parameters

ISP 26.95 Amps Peak Secondary Current
ISRMS 12.03 Amps Secondary RMS Current
IO_PEAK 7.00 Amps Secondary Peak Output Current
IO 7.00 Amps Average Power Supply Output Current
IRIPPLE 9.79 Amps Output Capacitor RMS Ripple Current
CMS 2407 Cmils Secondary Bare Conductor minimum circular

AWGS 16 AWG Secondary Wire Gauge (Rounded up to next

DIAS 1.29 mm Secondary Minimum Bare Conductor Diameter
ODS 3.57 mm Secondary Maximum Outside Diameter for

INSS 1.14 mm Maximum Secondary Insulation Wall Thickness

VOLTAGE STRESS PARAMETERS

VDRAIN 625 Volts Maximum Drain Voltage Estimate (Includes

PIVS 21 Volts Output Rectifier Maximum Peak Inverse

PIVB 49 Volts Bias Rectifier Maximum Peak Inverse Voltage

0.45 mm Gap Length (Lg > 0.1 mm)

338 Cmils/A

mp

m^2

(BM<3000)

and LP_MAX. Note: Recommended values for
adapters and external power supplies <=3600
Gauss

Peak to Peak)

insulation

thickness)

standard AWG value)

Primary Winding Current Capacity (200 < CMA
< 500)
Primary Winding Current density (3.8 < J <

9.75)

mils

larger standard AWG value)

Triple Insulated Wire

Effect of Leakage Inductance)

Voltage

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TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output

VO1 5.00
IO1_AVG 2.20 2.2 Amps Average DC Output Current
PO1_AVG 11.00 Watts Average Output Power
VD1 0.5 Volts Output Diode Forward Voltage Drop
NS1 3.00 Output Winding Number of Turns
ISRMS1 3.782 Amps Output Winding RMS Current
IRIPPLE1 3.08 Amps Output Capacitor RMS Ripple Current
PIVS1 21 Volts Output Rectifier Maximum Peak Inverse

CMS1 756 Cmils Output Winding Bare Conductor minimum

AWGS1 21 AWG Wire Gauge (Rounded up to next larger

DIAS1 0.73 mm Minimum Bare Conductor Diameter
ODS1 3.57 mm Maximum Outside Diameter for Triple Insulated

2nd output

VO2 12.00
IO2_AVG 2.00 Amps Average DC Output Current
PO2_AVG 24.00 Watts Average Output Power
VD2 0.7 Volts Output Diode Forward Voltage Drop
NS2 6.93 Output Winding Number of Turns
ISRMS2 3.438 Amps Output Winding RMS Current
IRIPPLE2 2.80 Amps Output Capacitor RMS Ripple Current
PIVS2 49 Volts Output Rectifier Maximum Peak Inverse

CMS2 688 Cmils Output Winding Bare Conductor minimum

AWGS2 21 AWG Wire Gauge (Rounded up to next larger

DIAS2 0.73 mm Minimum Bare Conductor Diameter
ODS2 1.54 mm Maximum Outside Diameter for Triple Insulated

3rd output

VO3
IO3_AVG Amps Average DC Output Current
PO3_AVG 0.00 Watts Average Output Power
VD3 0.7 Volts Output Diode Forward Voltage Drop
NS3 0.38 Output Winding Number of Turns
ISRMS3 0.000 Amps Output Winding RMS Current
IRIPPLE3 0.00 Amps Output Capacitor RMS Ripple Current
PIVS3 2 Volts Output Rectifier Maximum Peak Inverse

CMS3 0 Cmils Output Winding Bare Conductor minimum

AWGS3 N/A AWG Wire Gauge (Rounded up to next larger

DIAS3 N/A mm Minimum Bare Conductor Diameter
ODS3 N/A mm Maximum Outside Diameter for Triple Insulated

Total Continuous Output Power

Negative Output N/A If negative output exists enter Output number;

5 Volts Output Voltage

Voltage

circular mils

standard AWG value)

Wire

Volts Output Voltage

Voltage

circular mils

standard AWG value)

Wire

Volts Output Voltage

Voltage

circular mils

standard AWG value)

Wire

35 Watts Total Continuous Output Power

eg: If VO2 is negative output, enter 2

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8 Performance Data

All measurements performed at room temperature, 60 Hz input frequency.

8.1 Efficiency

Efficiency

84.5%

84.0%

83.5%

83.0%

82.5%

82.0%

81.5%

Efficiency (%)

81.0%

80.5%

80.0%

20.0% 40.0% 60.0% 80.0% 100.0%

115 VAC
230 VAC

Load (A)

Figure 6 – Efficiency vs. Input Voltage, Room Temperature, 60 Hz.

8.1.1 Active Mode CEC Measurement Data
All single output adapters, including those provided with products, for sale in California

st

after Jan 1

, 2008 must meet the California Energy Commission (CEC) requirement for
minimum active mode efficiency and no load input power. Minimum active mode
efficiency is defined as the average efficiency of 25, 50, 75 and 100% of rated output
power with the limit based on the nameplate output power:

Nameplate Output (PO) Minimum Efficiency in Active Mode of Operation

< 1 W

≥ 1 W to ≤ 49 W 0.09 × ln (PO) + 0.5 [ln = natural log]

> 49 W 0.85

0.49 × P

O

For adapters that are single input voltage only, then the measurement is made at the
rated single nominal input voltage (115 VAC or 230 VAC); for universal input adapters the
measurement is made at both nominal input voltages (115 VAC and 230 VAC).

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To meet the standar, the measured average efficiency (or efficiencies for universal input
supplies) must be greater than or equal to the efficiency specified by the CEC/Energy
Star standard.

Percent of
Full Load

25 80.6 80.5
50 82.7 83.7
75 83.0 83.9

100 82.7 84.0

Average 82.2 83.0

CEC
specified
minimum

average

efficiency (%)

Efficiency (%)

115 VAC 230 VAC

82.0*

*Although the CEC standard does not apply to this design, the data is provided for
reference

More states within the USA and other countries are adopting this standard, for the latest
up to date information please visit the PI Green Room:

http://www.powerint.com/greenroom/regulations.htm

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8.2 No-load Input Power

No-Load Input Power

0.260

0.240

0.220

0.200

0.180

Input Power (W)

0.160

0.140
85 105 125 145 165 185 205 225 245 265

AC Input (VAC)

Figure 7 – Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz.

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8.3 Available Standby Output Power

The chart below shows the available output power vs line voltage for an input power of 1
W, 2 W and 3 W. This measurement was taken by loading the 5 Volt output.

Available Output Power

1.800

1.600

1.400

1.200
1 W Input Power

1.000

0.800

Output Power (W)

0.600

2 W Input Power
3 W Input Power

0.400

0.200

85 105 125 145 165 185 205 225 245 265

Input Voltage (VAC)

Figure 8 – Available Standby Output Power for Fixed Levels of Input Power

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p

)

9 Regulation

9.1.1 Load

Load Regulation

13.0

12.0

11.0

10.0

9.0

8.0

7.0

Output Voltage (V)

6.0

5.0

4.0
0 5 10 15 20 25 30 35

5 V Output, 115 VAC

5 V Output, 230 VAC

12 V Output, 115 VAC

12 V Output, 230 VAC

Out

ut Power (W

Figure 9 – Load Regulation, Room Temperature

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9.1.2 Line

Line Regulation

13.00

12.00

11.00

10.00

9.00

8.00

7.00

Output Voltage (V)

6.00

5.00

4.00

5 V Output
12 V Output

85 135 185 235

AC Input (VAC)

Figure 10 – Line Regulation, Room Temperature, Full Load

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9.1.3 Cross Regulation Matrix
The table below shows the data for the outputs under various loading conditions at 90

and 265 VAC. The regulation on the 5 V output was within ±5% under all conditions.

90 VAC constant 50 mA load on 12 V 265 VAC constant 50 mA load on 12 V

IO (12 V) IO (5 V) VO (5 V) VO (12 V) IO (12 V) IO (5 V) VO (5 V) VO (12 V)

0.05 0.05 4.96 12.23 0.05 0.05 4.95 12.27

0.05 0.5 4.9 13.12 0.05 0.5 4.89 13.2

0.05 1 4.85 13.82 0.05 1 4.85 13.95

0.05 1.5 4.82 14.4 0.05 1.5 4.8 14.64

0.05 2.2 4.79 14.9 0.05 2.2 4.78 14.98

90 VAC - 12 V held constant at full load 265 VAC - 12 V held constant at full load

IO (12 V) IO (5 V) VO (5 V) VO (12 V) IO (12 V) IO (5 V) VO (5 V) VO (12 V)

2 0.05 4.99 11.7 2 0.05 4.99 11.66
2 0.5 4.97 12 2 0.5 4.97 11.97
2 1 4.96 12.14 2 1 4.96 12.1
2 1.5 4.95 12.27 2 1.5 4.95 12.22
2 2.2 4.94 12.4 2 2.2 4.94 12.33

90 VAC constant 50 mA load on 5 V 265 VAC constant 50 mA load on 5 V

IO (5 V) IO (12 V) VO (12 V) VO (5 V) IO (5 V) IO (12 V) VO (12 V) VO (5 V)

0.05 0.05 12.26 4.95 0.05 0.05 12.27 4.95

0.05 0.5 11.91 4.97 0.05 0.5 11.91 4.99

0.05 1 11.79 4.98 0.05 1 11.76 4.99

0.05 1.5 11.73 4.98 0.05 1.5 11.69 4.99

0.05 2 11.68 4.98 0.05 2 11.63 4.99

90 VAC constant 2.2 A load on 5 V 265 VAC constant 2.2 A load on 5 V

IO (5 V) IO (12 V) VO (12 V) VO (5 V) IO (5 V) IO (12 V) VO (12 V) VO (5 V)

2.2 0.05 14.96 4.78 2.2 0.05 14.87 4.8

2.2 0.5 12.91 4.91 2.2 0.5 12.96 4.91

2.2 1 12.54 4.94 2.2 1 12.55 4.93

2.2 1.5 12.42 4.94 2.2 1.5 12.98 4.94

2.2 2 12.36 4.94 2.2 2 12.32 4.94

Table 1 : Cross regulation data under various loading conditions

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10 Thermal Performance

Measurements were taken with no air flow across the power supply.

Item

Ambient

Output Capacitor (C17)

Transformer (T1)

Clamp Diode

TOPSwitch (U1)

Source pin

Rectifier (D8)

Table 2 – Thermal Performance, Full Load

Temperature (°C)

90 VAC 265 VAC

50 51

71 61

87 87

96 91

108 91

89 88

Figure 11 – Infrared Thermograph of Open Frame Operation, at Room Temperature

Page 27 of 40

90 VAC, 35 W load, 21ºC Ambient

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RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

11 Waveforms

11.1 Drain Voltage and Current, Normal Operation

Figure 12 – 90 VAC, Full Load.

Upper: V
Lower: I

, 100 V, 5 µs / div

DRAIN

, 0.5 A / div

DRAIN

11.2 Output Voltage Start-up Profile

Figure 14 – 5 Volt Start-up Profile, Full load;

90 VAC; 1 V/div, 5 ms / div.

Figure 13 – 265 VAC, Full Load

Upper: V
Lower: I

, 200 V, 5 µs / div

DRAIN

, 0.5 A / div

DRAIN

Figure 15 – 5 Volt Start-up Profile, Full load; 265

VAC; 1 V/div, 5 ms / div.

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Figure 16 – 12 Volt Start-up Profile, Full load;

90 VAC; 2 V/div, 5 ms / div

Figure 17 – 12 Volt Start-up Profile, Full load;

265 VAC; 2 V/div, 5 ms / div.

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11.3 Drain Voltage and Current Start-up Profile

Figure 18 – 90 VAC Input and Maximum Load.

Upper: V

Lower: I

, 100 V, 2 mS / div

DRAIN

, 0.5 A / div.

DRAIN

Figure 19 – 265 VAC Input and Maximum Load.

Upper: V

Lower: I

, 200 V, 2 mS / div

DRAIN

, 0.5 A / div.

DRAIN

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11.4 Load Transient Response (75% to 100% Load Step)

In the figures shown below, signal averaging was used to better enable viewing of the
load transient response. The oscilloscope was triggered using the load current step as a
trigger source. Since the output switching and line frequency occur essentially at random
with respect to the load transient, contributions to the output ripple from these sources
will average out, leaving the contribution only from the load step response.

Figure 20 – 5 Volt Transient Response, 90 VAC,

75-100-75% Load Step.
Output Voltage 20 mV/div, Output
Current 1 A / div, 10 ms / div.

Note

: 12 volt output maintained at full load

Figure 21 – 5 Volt Transient Response, 265 VAC,

75-100-75% Load Step
Output Voltage 20 mV/div, Output
Current 1 A / div, 10 ms / div.

Note

: 12 volt output maintained at full load

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Figure 22 –12 Volt output in response to 5 V

transient, 90 VAC, 75-100-75% Load
Step
Output Voltage 50 mV/div, Output
Current 1 A / div, 10 ms / div.

Figure 23 – 12 Volt output in response to 5 V

transient, 265 VAC, 75-100-75%
Load Step
Output Voltage 50 mV/div, Output
Current 1 A / div, 10 ms / div.

Note: 5 volt output maintained at full load
(Waveshape is combination of line ripple and
transient response - see figure 26)

Note: 5 volt output maintained at full load

11.5 Output Over-voltage Protection

The figures below show the performance of the output over-voltage protection circuit
when the control loop was opened.

Figure 24 –5 Volt output in response to open loop

R5 = 5.1 kΩ to configure hysteretic
shutdown.
Output Voltage 2 V/div, 1 s / div.

Figure 25 –5 Volt output in response to open loop

R5 = 20 Ω to configure latching
shutdown.
Output Voltage 2 V/div, 1 s / div.

Note: 12 V volt output maintained at no load

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24-Sep-07 RDR-142 35 W, TOP258PN Dual Output Supply

11.6 Output Ripple Measurements

11.6.1 Ripple Measurement Technique
For DC output ripple measurements, a modified oscilloscope test probe must be utilized

in order to reduce spurious signals due to pickup. Details of the probe modification are
provided below.

The 4987BA probe adapter is affixed with two capacitors tied in parallel across the probe
tip. The capacitors include one (1) 0.1 µF/50 V ceramic type and one (1) 1.0 µF/50 V
aluminum electrolytic. The aluminum electrolytic type capacitor is polarized, so proper

polarity across DC outputs must be maintained (see below).

Probe Ground

Probe Tip

Figure 23 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead Removed)

Figure 24 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter.

(Modified with wires for ripple measurement, and two parallel decoupling capacitors added)

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11.6.2 Measurement Results

Figure 26 – 5 V Ripple, 90 VAC, Full Load.

2 ms, 5 mV / div

Figure 28 – 12 V Ripple, 90 VAC, Full Load.

2 ms, 20 mV /div

Figure 27 – 5 V Ripple, 115 VAC, Full Load.

2 ms, 10 mV / div

Figure 29– 12 V Ripple, 115 VAC, Full Load.

2 ms, 20 mV /div

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12 Line Surge

Differential input line 1.2/50 µs surge testing was completed on a single test unit to
IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load
and operation was verified following each surge event.

Surge

Level (V)

+500 230 L to N 90 Pass

-500 230 L to N 270 Pass

+1000 230 L to N 90 Pass

-1000 230 L to N 270 Pass

+2000 230 L,N to G 90 Pass

-2000 230 L,N to G 270 Pass

Note: Unit passes under all test conditions.
Use a Slow Blow fuse at the input (F1) to increase differential surge withstand to 2 kV

Input

Voltage

(VAC)

Injection

Location

Injection

Phase (°)

Test Result

(Pass/Fail)

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13 Control Loop Measurements

13.1 90 VAC Maximum Load

Figure 30 – Gain-Phase Plot, 90 VAC, Maximum Steady State Load

Vertical Scale: Gain = 10 dB/div, Phase = 30 °/div.
Crossover Frequency = 2.0 kHz Phase Margin = 65°

13.2 265 VAC Maximum Load

Figure 31 – Gain-Phase Plot, 265 VAC, Maximum Steady State Load

Vertical Scale: Gain = 10 dB/div, Phase = 30 °/div.
Crossover Frequency = 350 Hz, Phase Margin = 90°

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14 Conducted EMI

Conducted EMI measurements were made with the output connected to the earth ground
connection on the LISN. The result below represents the worst case results.

Figure 32 – Conducted EMI, Neutral Conductor, Maximum Steady State Load, 230 VAC, 60 Hz, and

EN55022 B Limits.

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15 Revision History

Date Author Revision Description & changes Reviewed

24-Sep-07 SGK 1.0 Initial Release

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For the latest updates, visit our website: 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. 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.

PATENT INFORMATION

The products and applications illustrated herein (including 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, PeakSwitch, 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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East Street, Farnham
Surrey, GU9 7TJ
United Kingdom
Phone: [phone]
Fax: [phone]
e-mail: [e-mail]

APPLICATIONS HOTLINE

World Wide [phone]

APPLICATIONS FAX

World Wide [phone]

Page 39 of 40

Tel: [phone] Fax: [phone]

Power Integrations

www.powerint.com

RDR-142 35 W, TOP258PN Dual Output Supply 24-Sep-07

Page 40 of 40

Power Integrations, Inc.

Tel: [phone] Fax: [phone]
www.powerint.com