Power integrations TOP252GN, TOP253GN, TOP252PN, TOP253PN, TOP253MN Series Manual

...
TOP252-262 TOPSwitch-HX Family
Enhanced EcoSmart, Integrated Off-Line Switcher with Advanced Feature Set and Extended Power Range
Product Highlights
Lower System Cost, Higher Design Flexibility
New eSIP-7F and eSIP-7C packages
Low thermal impedance junction-to-case (2 °C per watt)
Low height is ideal for adapters where space is limited
Simple mounting using a clip to aid low cost manufacturing
Horizontal eSIP-7F package ideal for ultra low height adapter
and monitor applications
Extended package creepage distance from DRAIN pin to
adjacent pin and to heat sink
No heat sink required up to 35 W using P, G and M packages
with universal input voltage and up to 48 W at 230 VAC
Output overvoltage protection (OVP) is user programmable for
latching/non-latching shutdown with fast AC reset
Allows both primary and secondary sensing
Line undervoltage (UV) detection prevents turn-off glitches
Line overvoltage (OV) shutdown extends line surge limit
Accurate programmable current limit
Optimized line feed-forward for line ripple rejection
132 kHz frequency (254Y-258Y and all E/L packages) reduces
transformer and power supply size
Half frequency option for video applications
Frequency jittering reduces EMI filter cost
AC
IN
D
TOPSwitch-HX
S
Figure 1. Typical Flyback Application.
Heat sink is connected to SOURCE for low EMI
Improved auto-restart delivers <3% of maximum power in
V
CONTROL
C
FX
PI-4510-100206
DC
OUT
+
-
short circuit and open loop fault conditions
Accurate hysteretic thermal shutdown function automatically
recovers without requiring a reset
Fully integrated soft-start for minimum start-up stress
Extended creepage between DRAIN and all other pins
improves field reliability
Output Power Table
Product
5
TOP252PN/GN
TOP252MN 21 W 13 W
TOP253PN/GN
TOP253MN 43 W 29 W
TOP254PN/GN
TOP254MN 62 W 40 W
TOP255PN/GN
TOP255MN 81 W 52 W
TOP256PN/GN
TOP256MN 98 W 64 W
TOP257PN/GN
TOP257MN 119 W 78 W
TOP258PN/GN
TOP258MN 140 W 92 W
Table 1. Output Power Table. (for notes see page 2).
230 VAC ±15%
Adapter
1
Frame
9 W 15 W
15 W 25 W
16 W 28 W
19 W 30 W
21 W 34 W
25 W 41 W
29 W 48 W
Open
4
Peak3Adapter
2
21 W
38 W
47 W
54 W
63 W
70 W
77 W
85-265 VAC
Open
1
Frame
6 W 10 W
9 W 15 W
11 W 20 W
13 W 22 W
15 W 26 W
19 W 30 W
22 W 35 W
Peak
2
13 W
25 W
30 W
35 W
40 W
45 W
50 W
3
Product
5
230 VAC ±15% 85-265 VAC
Open
Adapter
1
Frame
Adapter
2
1
TOP252EN/EG 10 W 21 W 6 W 13 W TOP253EN/EG 21 W 43 W 13 W 29 W TOP254EN/YN/EG 30 W 62 W 20 W 43 W TOP255EN/YN/EG 40 W 81 W 26 W 57 W TOP255LN 40 W 81 W 26 W 57 W
TOP256EN/YN/EG 60 W 119 W 40 W 86 W
TOP256LN 60 W 88 W 40 W 64 W TOP257EN/YN/EG 85 W 157 W 55 W 119 W TOP257LN 85 W 105 W 55 W 78 W TOP258EN/YN/EG 105 W 195 W 70 W 148 W TOP258LN 105 W 122 W 70 W 92 W
TOP259EN/YN/EG 128 W 238 W 80 W 171 W
TOP259LN 128 W 162 W 80 W 120 W TOP260EN/YN/EG 147 W 275 W 93 W 200 W TOP260LN 147 W 190 W 93 W 140 W TOP261EN/YN/EG 177 W 333 W 118 W 254 W TOP261LN 177 W 244 W 118 W 177 W TOP262EN TOP262LN
6
6
177 W 333 W 118 W 254 W 177 W 244 W 118 W 177 W
Open
Frame
2
www.power.com August 2016
This Product is Covered by Patents and/or Pending Patent Applications.
TOP252-262
EcoSmart– Energy Efficient
Energy efficient over entire load range
No-load consumption
Less than 200 mW at 230 VAC
Standby power for 1 W input
>600 mW output at 110 VAC input
>500 mW output at 265 VAC input
Description
TOPSwitch™-HX cost effectively incorporates a 700 V power MOSFET, high voltage switched current source, PWM control, oscillator, thermal shutdown circuit, fault protection and other control circuitry onto a monolithic device.
Notes for Table 1:
1. Minimum continuous power in a typical non-ventilated enclosed adapter measured at +50 °C ambient. Use of an external heat sink will increase power capability.
2. Minimum continuous power in an open frame design at +50 °C ambient.
3. Peak power capability in any design at +50 °C ambient.
4. 230 VAC or 110/115 VAC with doubler.
5. Packages: P: DIP-8C, G: SMD-8C, M: SDIP-10C, Y: TO-220-7C, E: eSIP-7C, L: eSIP-7F. See part ordering information.
6. TOP261 and TOP262 have the same current limit set point. In some applications TOP262 may run cooler than TOP261 due to a lower R
for the larger device.
DS(ON)
Y Package Option for TOP259-261
In order to improve noise-immunity on large TOPSwitch-HX Y package parts, the F pin has been removed (TOP259-261YN are fixed at 66 kHz switching frequency) and replaced with a SIGNAL GROUND (G) pin. This pin acts as a low noise path for the C pin capacitor and the X pin resistor. It is only required for the TOP259-261YN package parts.
AC
IN
D
TOPSwitch-HX
S
Figure 2. Typical Flyback Application TOP259YN, TOP260YN and TOP261YN.
V
CONTROL
C
GX
PI-4973-122607
DC
OUT
+
-
2
Rev. J 08/16
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TOP252-262
Section List
Functional Block Diagram ....................................................................................................................................... 4
Pin Functional Description ...................................................................................................................................... 6
TOPSwitch-HX Family Functional Description ....................................................................................................... 7
CONTROL (C) Pin Operation .................................................................................................................................... 8
Oscillator and Switching Frequency .......................................................................................................................... 8
Pulse Width Modulator ............................................................................................................................................ 9
Maximum Load Cycle .............................................................................................................................................. 9
Error Amplifier .......................................................................................................................................................... 9
On-Chip Current Limit with External Programmability ............................................................................................... 9
Line Undervoltage Detection (UV) ........................................................................................................................... 10
Line Overvoltage Shutdown (OV) ............................................................................................................................ 11
Hysteretic or Latching Output Overvoltage Protection (OVP)...................................................................................11
Line Feed-Forward with DC
Remote ON/OFF and Synchronization .................................................................................................................... 13
Soft-Start ............................................................................................................................................................... 13
Shutdown/Auto-Restart ......................................................................................................................................... 13
Hysteretic Over-Temperature Protection ................................................................................................................. 13
Bandgap Reference ............................................................................................................................................... 13
High-Voltage Bias Current Source .......................................................................................................................... 13
Typical Uses of FREQUENCY (F) Pin ...................................................................................................................... 15
Typical Uses of VOLTAGE MONITOR (V) and EXTERNAL CURRENT LIMIT (X) Pins .......................................... 16
Typical Uses of MULTI-FUNCTION (M) Pin ........................................................................................................... 18
Application Examples .............................................................................................................................................. 21
A High Efficiency, 35 W, Dual Output – Universal Input Power Supply ..................................................................... 21
A High Efficiency, 150 W, 250-380 VDC Input Power Supply .................................................................................. 22
A High Efficiency, 20 W Continuous – 80 W Peak, Universal Input Power Supply ................................................... 23
A High Efficiency, 65 W, Universal Input Power Supply ........................................................................................... 24
Key Application Considerations .............................................................................................................................. 25
TOPSwitch-HX vs.TOPSwitch-GX
TOPSwitch-HX Design Considerations .................................................................................................................. 26
TOPSwitch-HX Layout Considerations ................................................................................................................... 27
Quick Design Checklist .......................................................................................................................................... 31
Design Tools .......................................................................................................................................................... 31
Product Specifications and Test Conditions .......................................................................................................... 32
Typical Performance Characteristics .................................................................................................................... 39
Package Outlines .................................................................................................................................................... 43
Part Ordering Information ........................................................................................................................................ 47
Reduction .............................................................................................................. 13
MAX
.......................................................................................................................
. 25
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3
Rev. J 08/16
TOP252-262
SOURCE (S)
SOURCE (S)
CONTROL (C)
MULTI-
FUNCTION (M)
Z
C
SHUNT REGULATOR/
ERROR AMPLIFIER
I
FB
CURRENT
LIMIT
ADJUST
LINE
SENSE
V
C
0
INTERNAL SUPPLY
1
DRAIN (D)
-
+
-
5.8 V
+
V
I (LIMIT)
ON/OFF
+ V
V
BG
T
5.8 V
4.8 V
INTERNAL UV
COMPARATOR
-
STOP LOGIC
DC
MAX
STOP
OSCILLATOR
WITH JITTER
OV/
OVPV
UV
DC
MAX
F REDUCTION
SOFT
START
SOFT START
D
MAX
CLOCK
÷ 16
SHUTDOWN/
AUTO-RESTART
HYSTERETIC
THERMAL
SHUTDOWN
SRQ
K
PS(UPPER)
K
PS(LOWER)
CURRENT LIMIT
COMPARATOR
+
-
+
-
+
SOURCE (S)
CONTROLLED
TURN-ON
GATE DRIVER
LEADING
EDGE
BLANKING
F REDUCTION
SOFT START I
K
PS(UPPER)
K
PS(LOWER)
FB
I
PS(UPPER)
I
PS(LOWER)
PWM
OFF
Figure 3a. Functional Block Diagram (P and G Packages).
CONTROL (C)
EXTERNAL
CURRENT
LIMIT (X)
VOLTAGE
MONITOR (V)
Z
C
SHUNT REGULATOR/
ERROR AMPLIFIER
I
FB
-
+
CURRENT
LIMIT
ADJUST
V
1 V
LINE
SENSE
V
C
5.8 V
5.8 V
V
I (LIMIT)
ON/OFF
+ V
BG
T
4.8 V
STOP LOGIC
OV/
OVPV
UV
DC
MAX
I
PS(UPPER)
I
PS(LOWER)
+
-
INTERNAL UV
COMPARATOR
STOP
OSCILLATOR
DC
MAX
WITH JITTER
F REDUCTION
F REDUCTION
SOFT START I
FB
I
PS(UPPER)
I
PS(LOWER)
PWM
SOFT
START
SOFT START
D
MAX
CLOCK
OFF
0
1
÷ 16
SHUTDOWN/
AUTO-RESTART
HYSTERETIC
THERMAL
SHUTDOWN
INTERNAL SUPPLY
SRQ
I
PS(UPPER)
I
PS(LOWER)
CURRENT LIMIT
COMPARATOR
CONTROLLED
TURN-ON
GATE DRIVER
PI-4508-120307
-
+
-
+
-
+
SOURCE (S)
LEADING
EDGE
BLANKING
DRAIN (D)
Figure 3b. Functional Block Diagram (M Package).
4
Rev. J 08/16
PI-4643-040507
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TOP252-262
SOURCE (S)
GROUND (G)
SOURCE (S)
CONTROL (C)
EXTERNAL CURRENT
LIMIT (X)
VOLTAGE
MONITOR (V)
FREQUENCY (F)
V
Z
C
SHUNT REGULATOR/
ERROR AMPLIFIER
-
+
I
FB
CURRENT
LIMIT
ADJUST
V
BG
1 V
LINE
SENSE
C
+ V
OVPV
5.8 V
V
I (LIMIT)
ON/OFF
T
DC
OV/
UV
MAX
K
PS(UPPER)
K
PS(LOWER)
5.8 V
4.8 V
INTERNAL UV
COMPARATOR
STOP LOGIC
DC
66k/132k
SOFT START I
FB
I
PS(UPPER)
I
PS(LOWER)
+
-
MAX
F REDUCTION
F REDUCTION
SOFT
STOP
START
OSCILLATOR WITH JITTER
PWM
SOFT START
D
MAX
CLOCK
OFF
0
1
÷ 16
SHUTDOWN/
AUTO-RESTART
HYSTERETIC
THERMAL
SHUTDOWN
INTERNAL SUPPLY
SRQ
K
PS(UPPER)
K
PS(LOWER)
CURRENT LIMIT
COMPARATOR
CONTROLLED
TURN-ON
GATE DRIVER
-
+
-
+
-
+
SOURCE (S)
LEADING
EDGE
BLANKING
DRAIN (D)
Figure 3c. Functional Block Diagram (TOP254-258 YN Package and all eSIP Packages).
CONTROL (C)
EXTERNAL CURRENT
LIMIT (X)
VOLTAGE
MONITOR (V)
Z
C
SHUNT REGULATOR/
ERROR AMPLIFIER
I
FB
-
+
CURRENT
LIMIT
ADJUST
V
1 V
LINE
SENSE
V
C
+
5.8 V
-
5.8 V
V
I (LIMIT)
ON/OFF
+ V
BG
T
4.8 V
INTERNAL UV
COMPARATOR
SOFT START
STOP LOGIC
SOFT
DC
MAX
STOP
START
OSCILLATOR WITH JITTER
D
MAX
CLOCK
OV/
OVPV
UV
DC
MAX
F REDUCTION
F REDUCTION
SOFT START
K
PS(UPPER)
K
PS(LOWER)
I
FB
I
PS(UPPER)
I
PS(LOWER)
PWM
OFF
0
1
÷ 16
SHUTDOWN/
AUTO-RESTART
HYSTERETIC
THERMAL
SHUTDOWN
INTERNAL SUPPLY
SRQ
K
PS(UPPER)
K
PS(LOWER)
CURRENT LIMIT
COMPARATOR
CONTROLLED
GATE DRIVER
-
+
-
+
-
+
SOURCE (S)
TURN-ON
LEADING
BLANKING
PI-4511-012810
DRAIN (D)
EDGE
Figure 3d. Functional Block Diagram TOP259YN, TOP260YN, TOP261YN.
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PI-4974-122607
SIGNAL
5
Rev. J 08/16
TOP252-262
Pin Functional Description
DRAIN (D) Pin:
High-voltage power MOSFET DRAIN pin. The internal start-up bias current is drawn from this pin through a switched high­voltage current source. Internal current limit sense point for drain current.
CONTROL (C) Pin:
Error amplifier and feedback current input pin for duty cycle control. Internal shunt regulator connection to provide internal bias current during normal operation. It is also used as the connection point for the supply bypass and auto-restart/ compensation capacitor.
EXTERNAL CURRENT LIMIT (X) Pin (Y, M, E and L package):
Input pin for external current limit adjustment and remote ON/OFF. A connection to SOURCE pin disables all functions on this pin.
E Package (eSIP-7C)
Exposed Pad (Hidden) Internally Connected to SOURCE Pin
Y Package (TO-220-7C)
Note: Y package for TOP259-261
VOLTAGE MONITOR (V) Pin (Y & M package only):
Input for OV, UV, line feed forward with DC
reduction, output
MAX
overvoltage protection (OVP), remote ON/OFF and device reset. A connection to the SOURCE pin disables all functions on this pin.
MULTI-FUNCTION (M) Pin (P & G packages only):
This pin combines the functions of the VOLTAGE MONITOR (V) and EXTERNAL CURRENT LIMIT (X) pins of the Y package into one pin. Input pin for OV, UV, line feed forward with DC
V
X
R
12 k
VUV = IUV × R V
=
OV
For R
4 M
VUV = 102.8 VDC V
DC
MAX
DC
MAX
C
For RIL = 12 k
I
See Figure 55b for
IL
other resistor values (R I
LS + VV
I
R
×
OV
LS + VV
= 4 M
LS
= 451 VDC
OV
@100 VDC = 76% @375 VDC = 41%
= 61%
LIMIT
) to select different
IL
values.
LIMIT
+
R
LS
DC
Input
Voltage
D
CONTROL
S
-
Figure 5. TOP254-258 Y and All M/E/L Package Line Sense and Externally Set
Current Limit.
MAX
(IV = IUV)
(IV = IOV)
PI-4711-021308
V
7D5S4F3C2X1
L Package (eSIP-7F)
Lead Bend Outward from Drawing (Refer to eSIP-7F Package
7D5S4F3C2X1
V
Outline Drawing)
M Package
V
1
2
X
3
C
5
D
10
S
9
S
S
8
S
7
6
S
P and G Package
M
1
C
2
4
D
Figure 4. Pin Configuration (Top View).
S
8
7
S
6
S
S
5
Tab Internally Connected to SOURCE Pin
V
Y Package (TO-220-7C)
Note: Y package for TOP254-258
Tab Internally Connected to SOURCE Pin
V
7D5G4S3C2X1
7D5F4S3C2X1
PI-4644-091108
4 M
V
X G
VUV = IUV × R V
I
=
×
OV
OV
= 4 M
For R
LS
VUV = 102.8 VDC
= 451 VDC
V
OV
DC
@100 VDC = 76%
MAX
@375 VDC = 41%
DC
MAX
C
For RIL = 12 k
I
LIMIT
See Figure 55b for other resistor values
) to select different
(R
IL
values.
I
LIMIT
+
R
LS
DC
Input
Voltage
-
Figure 6. TOP259-261 Y Package Line Sense and External Current Limit.
D
S
CONTROL
R
IL
12 k
LS + VV
R
LS + VV
= 61%
(IV = IUV)
(IV = IOV)
+
DC
Input
Voltage
D M
-
Figure 7. P/G Package Line Sense.
S
R
LS
CONTROL
4 M
VUV = IUV × R V
I
=
×
OV
OV
= 4 M
For R
LS
= 102.8 VDC
V
UV
V
DC DC
C
451 VDC
=
OV
@100 VDC = 76%
MAX
@375 VDC = 41%
MAX
LS + VM
R
LS + VM
PI-4712-120307
(IM = IUV) (IM = IOV)
PI-4983-021308
6
Rev. J 08/16
www.power.com
+
DC
Input
Voltage
D M
R
IL
-
Figure 8. P/G Package Externally Set Current Limit.
CONTROL
S
C
For R
= 12 k
IL
= 61%
I
LIMIT
For R
= 19 k
IL
= 37%
I
LIMIT
See Figure 55b for other resistor values (R select different I
) to
IL
values.
LIMIT
PI-4713-021308
Auto-Restart
78
Duty Cycle (%) Drain Peak Current
100
TOP252-262
Slope = PWM Gain
(constant over load range)
CONTROL
Current
reduction, output overvoltage protection (OVP), external current limit adjustment, remote ON/OFF and device reset. A connection to SOURCE pin disables all functions on this pin and makes TOPSwitch-HX operate in simple three terminal mode (like TOPSwitch-II).
FREQUENCY (F) Pin (TOP254-258Y, and all E and L packages):
Input pin for selecting switching frequency 132 kHz if connected to SOURCE pin and 66 kHz if connected to CONTROL pin. The switching frequency is internally set for fixed 66 kHz operation in the P, G, M package and TOP259YN, TOP260YN an d TO P261YN.
SIGNAL GROUND (G) Pin (TOP259YN, TOP260YN & TOP261YN only):
Return for C pin capacitor and X pin resistor.
SOURCE (S) Pin:
Output MOSFET source connection for high voltage power return. Primary side control circuit common and reference point.
TOPSwitch-HX Family Functional Description
Like TOPSwitch-GX, TOPSwitch-HX is an integrated switched mode power supply chip that converts a current at the control input to a duty cycle at the open drain output of a high voltage power MOSFET. During normal operation the duty cycle of the power MOSFET decreases linearly with increasing CONTROL pin current as shown in Figure 9.
In addition to the three terminal TOPSwitch features, such as the high voltage start-up, the cycle-by-cycle current limiting, loop compensation circuitry, auto-restart and thermal shutdown, the TOPSwitch-HX incorporates many additional functions that reduce system cost, increase power supply performance and design flexibility. A patented high voltage CMOS technology allows both the high-voltage power MOSFET and all the low voltage control circuitry to be cost effectively integrated onto a single monolithic chip.
Three terminals, FREQUENCY, VOLTAGE-MONITOR, and EXTERNAL CURRENT LIMIT (available in Y and E/L packages),
55
25
To Current Limit Ratio (%)
CONTROL
Current
Full Frequency Mode
132
Variable
Frequency
66
Jitter
Frequency (kHz)
30
IB I
CD1
Figure 9. Control Pin Characteristics (Multi-Mode Operation).
I
C01
Mode
I
C02
I
C03
I
Low
Frequency
Mode
Multi-Cycle Modulation
CONTROL
COFF
Current
PI-4645-041107
two terminals, VOLTAGE-MONITOR and EXTERNAL CURRENT LIMIT (available in M package) or one terminal MULTI-FUNCTION (available in P and G package) have been used to implement some of the new functions. These terminals can be connected to the SOURCE pin to operate the TOPSwitch-HX in a TOPSwitch-like three terminal mode. However, even in this three terminal mode, the TOPSwitch-HX offers many transparent features that do not require any external components:
1. A fully integrated 17 ms soft-start significantly reduces or eliminates output overshoot in most applications by sweeping both current limit and frequency from low to high to limit the peak currents and voltages during start-up.
2. A maximum duty cycle (DC
) of 78% allows smaller input
MAX
storage capacitor, lower input voltage requirement and/or higher power capability.
3. Multi-mode operation optimizes and improves the power supply efficiency over the entire load range while maintaining good cross regulation in multi-output supplies.
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7
Rev. J 08/16
TOP252-262
4. Switching frequency of 132 kHz reduces the transformer size with no noticeable impact on EMI.
5. Frequency jittering reduces EMI in the full frequency mode at high load condition.
6. Hysteretic over-temperature shutdown ensures automatic recovery from thermal fault. Large hysteresis prevents circuit board overheating.
7. Packages with omitted pins and lead forming provide large drain creepage distance.
8. Reduction of the auto-restart duty cycle and frequency to improve the protection of the power supply and load during open loop fault, short circuit, or loss of regulation.
9. Tighter tolerances on I2f power coefficient, current limit reduction, PWM gain and thermal shutdown threshold.
The VOLTAGE-MONITOR (V) pin is usually used for line sensing by connecting a 4 MW resistor from this pin to the rectified DC high voltage bus to implement line overvoltage (OV), under­voltage (UV) and dual-slope line feed-forward with DC
MAX
reduction. In this mode, the value of the resistor determines the OV/UV thresholds and the DC
is reduced linearly with a dual
MAX
slope to improve line ripple rejection. In addition, it also provides another threshold to implement the latched and hysteretic output overvoltage protection (OVP). The pin can also be used as a remote ON/OFF using the I
threshold.
UV
The EXTERNAL CURRENT LIMIT (X) pin can be used to reduce the current limit externally to a value close to the operating peak current, by connecting the pin to SOURCE through a resistor. This pin can also be used as a remote ON/OFF input.
For the P and G package the VOLTAGE-MONITOR and EXTERNAL CURRENT LIMIT pin functions are combined on one MULTI-FUNCTION (M) pin. However, some of the functions become mutually exclusive.
The FREQUENCY (F) pin in the TOP254-258 Y and E/L packages set the switching frequency in the full frequency PWM mode to the default value of 132 kHz when connected to SOURCE pin. A half frequency option of 66 kHz can be chosen by connecting this pin to the CONTROL pin instead. Leaving this pin open is not recommended. In the P, G and M packages and the TOP259-261 Y packages, the frequency is set internally at 66 kHz in the full frequency PWM mode.
CONTROL (C) Pin Operation
The CONTROL pin is a low impedance node that is capable of receiving a combined supply and feedback current. During normal operation, a shunt regulator is used to separate the feedback signal from the supply current. CONTROL pin voltage V
is the supply voltage for the control circuitry including the
C
MOSFET gate driver. An external bypass capacitor closely connected between the CONTROL and SOURCE pins is required to supply the instantaneous gate drive current. The total amount of capacitance connected to this pin also sets the auto-restart timing as well as control loop compensation. When rectified DC high voltage is applied to the DRAIN pin during start-up, the MOSFET is initially off, and the CONTROL pin capacitor is charged through a switched high voltage
current source connected internally between the DRAIN and CONTROL pins. When the CONTROL pin voltage V
reaches
C
approximately 5.8 V, the control circuitry is activated and the soft-start begins. The soft-start circuit gradually increases the drain peak current and switching frequency from a low starting value to the maximum drain peak current at the full frequency over approximately 17 ms. If no external feedback/supply current is fed into the CONTROL pin by the end of the soft-start, the high voltage current source is turned off and the CONTROL pin will start discharging in response to the supply current drawn by the control circuitry. If the power supply is designed properly, and no fault condition such as open loop or shorted output exists, the feedback loop will close, providing external CONTROL pin current, before the CONTROL pin voltage has had a chance to discharge to the lower threshold voltage of approximately 4.8 V (internal supply undervoltage lockout threshold). When the externally fed current charges the CONTROL pin to the shunt regulator voltage of 5.8 V, current in excess of the consumption of the chip is shunted to SOURCE through an NMOS current mirror as shown in Figure 3. The output current of that NMOS current mirror controls the duty cycle of the power MOSFET to provide closed loop regulation. The shunt regulator has a finite low output impedance Z
that
C
sets the gain of the error amplifier when used in a primary feedback configuration. The dynamic impedance Z
of the
C
CONTROL pin together with the external CONTROL pin capacitance sets the dominant pole for the control loop.
When a fault condition such as an open loop or shorted output prevents the flow of an external current into the CONTROL pin, the capacitor on the CONTROL pin discharges towards 4.8 V. At 4.8 V, auto-restart is activated, which turns the output MOSFET off and puts the control circuitry in a low current standby mode. The high-voltage current source turns on and charges the external capacitance again. A hysteretic internal supply undervoltage comparator keeps V
within a window of
C
typically 4.8 V to 5.8 V by turning the high-voltage current source on and off as shown in Figure 11. The auto-restart circuit has a divide-by-sixteen counter, which prevents the output MOSFET from turning on again until sixteen discharge/ charge cycles have elapsed. This is accomplished by enabling the output MOSFET only when the divide-by-sixteen counter reaches the full count (S15). The counter effectively limits TOPSwitch-HX power dissipation by reducing the auto-restart duty cycle to typically 2%. Auto-restart mode continues until output voltage regulation is again achieved through closure of the feedback loop.
Oscillator and Switching Frequency
The internal oscillator linearly charges and discharges an internal capacitance between two voltage levels to create a triangular waveform for the timing of the pulse width modulator. This oscillator sets the pulse width modulator/current limit latch at the beginning of each cycle.
The nominal full switching frequency of 132 kHz was chosen to minimize transformer size while keeping the fundamental EMI frequency below 150 kHz. The FREQUENCY pin (available only in TOP254-258 Y and E, L packages), when shorted to the CONTROL pin, lowers the full switching frequency to 66 kHz
8
Rev. J 08/16
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TOP252-262
PI-4530-041107
f
+
Switching
Frequency
V
DRAIN
Figure 10. Switching Frequency Jitter (Idealized V
OSC
f
-
OSC
4 ms
Time
Waveforms).
DRAIN
(half frequency), which may be preferable in some cases such as noise sensitive video applications or a high efficiency standby mode. Otherwise, the FREQUENCY pin should be connected to the SOURCE pin for the default 132 kHz. In the M, P and G packages and the TOP259-261 Y package option, the full frequency PWM mode is set at 66 kHz, for higher efficiency and increased output power in all applications.
To further reduce the EMI level, the switching frequency in the full frequency PWM mode is jittered (frequency modulated) by approximately ±2.5 kHz for 66 kHz operation or ±5 kHz for 132 kHz operation at a 250 Hz (typical) rate as shown in Figure 10. The jitter is turned off gradually as the system is entering the variable frequency mode with a fixed peak drain current.
Pulse Width Modulator
The pulse width modulator implements multi-mode control by driving the output MOSFET with a duty cycle inversely proportional to the current into the CONTROL pin that is in excess of the internal supply current of the chip (see Figure 9). The feedback error signal, in the form of the excess current, is filtered by an RC network with a typical corner frequency of 7 kHz to reduce the effect of switching noise in the chip supply current generated by the MOSFET gate driver.
To optimize power supply efficiency, four different control modes are implemented. At maximum load, the modulator operates in full frequency PWM mode; as load decreases, the modulator automatically transitions, first to variable frequency PWM mode, then to low frequency PWM mode. At light load, the control operation switches from PWM control to multi-cycle­modulation control, and the modulator operates in multi-cycle­modulation mode. Although different modes operate differently to make transitions between modes smooth, the simple relationship between duty cycle and excess CONTROL pin current shown in Figure 9 is maintained through all three PWM modes. Please see the following sections for the details of the operation of each mode and the transitions between modes.
Full Frequency PWM mode: The PWM modulator enters full frequency PWM mode when the CONTROL pin current (I reaches I kept constant at f
. In this mode, the average switching frequency is
B
(66 kHz for P, G and M packages and
OSC
C
)
TOP259-261 Y, pin selectable 132 kHz or 66 kHz for Y and E/L
packages). Duty cycle is reduced from DC reduction of the on-time when I
is increased beyond IB. This
C
through the
MAX
operation is identical to the PWM control of all other TOPSwitch families. TOPSwitch-HX only operates in this mode if the cycle-by-cycle peak drain current stays above k where k
is 55% (typical) and I
PS(UPPER)
(set) is the current limit
LIMIT
PS(UPPER)*ILIMIT
(set),
externally set via the X or M pin.
Variable Frequency PWM mode: When peak drain current is lowered to k
PS(UPPER)
* I
(set) as a result of power supply load
LIMIT
reduction, the PWM modulator initiates the transition to variable frequency PWM mode, and gradually turns off frequency jitter. In this mode, peak drain current is held constant at k I
(set) while switching frequency drops from the initial full
LIMIT
frequency of f frequency of f
(132 kHz or 66 kHz) towards the minimum
OSC
(30 kHz typical). Duty cycle reduction is
MCM(MIN)
PS(UPPER)
*
accomplished by extending the off-time.
Low Frequency PWM mode: When switching frequency reaches f
(30 kHz typical), the PWM modulator starts to
MCM(MIN)
transition to low frequency mode. In this mode, switching frequency is held constant at f
and duty cycle is reduced,
MCM(MIN)
similar to the full frequency PWM mode, through the reduction of the on-time. Peak drain current decreases from the initial value of k k
PS(LOW ER)*ILIMIT
* I
PS(UPPER)
(set), where k
(set) towards the minimum value of
LIMIT
is 25% (typical) and I
PS(LOW ER)
LIMIT
(set) is
the current limit externally set via the X or M pin.
Multi-Cycle-Modulation mode: When peak drain current is lowered to k
PS(LOW ER)*ILIMIT
(set), the modulator transitions to multi-cycle-modulation mode. In this mode, at each turn-on, the modulator enables output switching for a period of T at the switching frequency of f at 30 kHz) with the peak drain current of k
(4 or 5 consecutive pulses
MCM(MIN)
PS(LOW ER)*ILIMIT
stays off until the CONTROL pin current falls below I
MCM(MIN)
(set), and
. This
C(OFF)
mode of operation not only keeps peak drain current low but also minimizes harmonic frequencies between 6 kHz and 30 kHz. By avoiding transformer resonant frequency this way, all potential transformer audible noises are greatly suppressed.
Maximum Duty Cycle
The maximum duty cycle, DC
, is set at a default maximum
MAX
value of 78% (typical). However, by connecting the VOLTAGE­MONITOR or MULTI-FUNCTION pin (depending on the package) to the rectified DC high voltage bus through a resistor with appropriate value (4 MW typical), the maximum duty cycle can be made to decrease from 78% to 40% (typical) when input line voltage increases from 88 V to 380 V, with dual gain slopes.
Error Amplifier
The shunt regulator can also perform the function of an error amplifier in primary side feedback applications. The shunt regulator voltage is accurately derived from a temperature­compensated bandgap reference. The CONTROL pin dynamic impedance Z CONTROL pin clamps external circuit signals to the V
sets the gain of the error amplifier. The
C
voltage
C
level. The CONTROL pin current in excess of the supply current is separated by the shunt regulator and becomes the feedback current I
for the pulse width modulator.
fb
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9
Rev. J 08/16
TOP252-262
V
V
LINE
0 V
~
~
~
UV
~
~
~
~
~
~
~
S14
S15
V
C
0 V
V
DRAIN
0 V
V
OUT
0 V
1
Note: S0 through S15 are the output states of the auto-restart counter
Figure 11. Typical Waveforms for (1) Power Up (2) Normal Operation (3) Auto-Restart (4) Power Down.
2
On-Chip Current Limit with External Programmability
The cycle-by-cycle peak drain current limit circuit uses the output MOSFET ON-resistance as a sense resistor. A current limit comparator compares the output MOSFET on-state drain to source voltage V current causes V
with a threshold voltage. High drain
DS(ON)
to exceed the threshold voltage and turns
DS(ON)
the output MOSFET off until the start of the next clock cycle. The current limit comparator threshold voltage is temperature compensated to minimize the variation of the current limit due to temperature related changes in R The default current limit of TOPSwitch-HX is preset internally.
S13 S12 S0 S15 S13 S12 S0 S15S14
~
~
~
~
~
~
of the output MOSFET.
DS(ON)
~
~
~
~
~
~
3
on. The leading edge blanking time has been set so that, if a power supply is designed properly, current spikes caused by primary-side capacitances and secondary-side rectifier reverse recovery time should not cause premature termination of the switching pulse.
The current limit is lower for a short period after the leading edge blanking time. This is due to dynamic characteristics of the MOSFET. During startup and fault conditions the controller prevents excessive drain currents by reducing the switching frequency.
However, with a resistor connected between EXTERNAL CURRENT LIMIT (X) pin (Y, E/L and M packages) or MULTI­FUNCTION (M) pin (P and G package) and SOURCE pin (for TOP259-261 Y, the X pin is connected to the SIGNAL GROUND (G) pin), current limit can be programmed externally to a lower level between 30% and 100% of the default current limit. By setting current limit low, a larger TOPSwitch-HX than necessary for the power required can be used to take advantage of the lower R
for higher efficiency/smaller heat sinking
DS(ON)
requirements. TOPSwitch-HX current limit reduction initial tolerance through the X pin (or M pin) has been improved significantly compare with previous TOPSwitch-GX. With a second resistor connected between the EXTERNAL CURRENT LIMIT (X) pin (Y, E/L and M packages) or MULTI-FUNCTION (M) pin (P and G package) and the rectified DC high voltage bus, the current limit is reduced with increasing line voltage, allowing a true power limiting operation against line variation to be implemented. When using an RCD clamp, this power limiting technique reduces maximum clamp voltage at high line. This allows for higher reflected voltage designs as well as reducing clamp dissipation.
Line Undervoltage Detection (UV)
At power up, UV keeps TOPSwitch-HX off until the input line voltage reaches the undervoltage threshold. At power down, UV prevents auto-restart attempts after the output goes out of regulation. This eliminates power down glitches caused by slow discharge of the large input storage capacitor present in applications such as standby supplies. A single resistor connected from the VOLTAGE-MONITOR pin (Y, E/L and M packages) or MULTI-FUNCTION pin (P and G packages) to the rectified DC high voltage bus sets UV threshold during power up. Once the power supply is successfully turned on, the UV threshold is lowered to 44% of the initial UV threshold to allow extended input voltage operating range (UV low threshold). If the UV low threshold is reached during operation without the power supply losing regulation, the device will turn off and stay off until UV (high threshold) has been reached again. If the power supply loses regulation before reaching the UV low threshold, the device will enter auto-restart. At the end of each auto-restart cycle (S15), the UV comparator is enabled. If the UV high threshold is not exceeded, the MOSFET will be disabled during the next cycle (see Figure 11). The UV feature
The leading edge blanking circuit inhibits the current limit
can be disabled independent of the OV feature.
comparator for a short time after the output MOSFET is turned
S14
2
S13
S12
~
~
~
~
~
~
4
S0 S15
S15
5.8 V
4.8 V
PI-4531-121206
10
Rev. J 08/16
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TOP252-262
Line Overvoltage Shutdown (OV)
The same resistor used for UV also sets an overvoltage threshold, which, once exceeded, will force TOPSwitch-HX to stop switching instantaneously (after completion of the current switching cycle). If this condition lasts for at least 100 ms, the TOPSwitch-HX output will be forced into off state. Unlike with TOPSwitch-GX, however, when the line voltage is back to
clamp network, bias winding return or power traces from other converters. If the line sensing features are used, then the sense resistors must be placed within 10 mm of the V-pin to minimize the V-pin node area. The DC bus should then be routed to the line sense resistors. Note that external capacitance must not be connected to the V-pin as this may cause misoperation of the V pin related functions.
normal with a small amount of hysteresis provided on the OV threshold to prevent noise triggering, the state machine sets to S13 and forces TOPSwitch-HX to go through the entire auto­restart sequence before attempting to switch again. The ratio of OV and UV thresholds is preset at 4.5, as can be seen in Figure 12. When the MOSFET is off, the rectified DC high voltage surge capability is increased to the voltage rating of the MOSFET (700 V), due to the absence of the reflected voltage and leakage spikes on the drain. The OV feature can be disabled independent of the UV feature.
Hysteretic or Latching Output Overvoltage Protection (OVP)
The detection of the hysteretic or latching output overvoltage protection (OVP) is through the trigger of the line overvoltage threshold. The V-pin or M-pin voltage will drop by 0.5 V, and the controller measures the external attached impedance immediately after this voltage drops. If I
or IM exceeds I
V
OV(LS)
(336 mA typical) longer than 100 ms, TOPSwitch-HX will latch into a permanent off state for the latching OVP. It only can be reset if V up-reset threshold (V
or VM goes below 1 V or VC goes below the power-
V
) and then back to normal.
C(RESET )
In order to reduce the no-load input power of TOPSwitch-HX designs, the V-pin (or M-pin for P Package) operates at very low currents. This requires careful layout considerations when designing the PCB to avoid noise coupling. Traces and components connected to the V-pin should not be adjacent to any traces carrying switching currents. These include the drain,
or IM does not exceed I
V
100 ms, TOPSwitch-HX will initiate the line overvoltage and the hysteretic OVP. Their behavior will be identical to the line overvoltage shutdown (OV) that has been described in detail in the previous section.
or exceeds no longer than
OV(LS)
If I
Voltage Monitor and External Current Limit Pin Table*
Figure Number 16 17 18 19 20 21 22 23 24 25 26 27 28
Three Terminal Operation
Line Undervoltage
Line Overvoltage
Line Feed-Forward (DC
Output Overvoltage Protection
Overload Power Limiting
External Current Limit
Remote ON/OFF
Device Reset
*This table is only a partial list of many VOLTAGE MONITOR and EXTERNAL CURRENT LIMIT Pin Configurations that are possible.
MAX
)
3
3 3 3 3 3 3
3 3 3 3 3 3
3 3 3 3 3
3 3
3
3 3 3 3 3
3 3 3
3
Table 2. VOLTAGE MONITOR (V) Pin and EXTERNAL CURRENT LIMIT (X) Pin Configuration Options.
Multi-Function Pin Table*
Figure Number 29 30 31 32 33 34 35 36 37 38 39 40
Three Terminal Operation
Line Undervoltage
Line Overvoltage
Line Feed-Forward (DC
Output Overvoltage Protection
Overload Power Limiting
External Current Limit
Remote ON/OFF
Device Reset
*This table is only a partial list of many MULTI-FUNCTIONAL Pin Configurations that are possible.
Table 3. MULTI-FUNCTION (M) Pin Configuration Options.
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MAX
)
3
3 3 3 3
3 3 3 3
3 3 3
3 3
3
3 3 3 3
3 3 3
3
11
Rev. J 08/16
TOP252-262
M Pin
V Pin X Pin
Output
MOSFET
Switching
Current
Limit
Maximum
Duty Cycle
(Enabled)
(Disabled)
I
(Default)
LIMIT
DC
(78%)
MAX
I
REM(N)
I
UV
Disabled when supply output goes out of regulation
I
OV
I
OV(LS)
(Non-Latching) (Latching)
I
I
I
V
BG
Pin Voltage
-250 -200 -150 -100 -50 0 25 50 75 100 125 336
X and V Pins (Y, E, L and M Packages) and M Pin (P and G Packages) Current (µA)
Note: This figure provides idealized functional characteristics with typical performance values. Please refer to the parametric table and typical performance characteristics sections of the data sheet for measured data. For a detailed description of each functional pin operation refer to the Functional Description section of the data sheet.
Figure 12. MULTI-FUNCTION (P and G package). VOLTAGE MONITOR and EXTERNAL CURRENT LIMIT (Y, E/L and M package) Pin Characteristics.
The circuit examples shown in Figures 41, 42 and 43 show a simple method for implementing the primary sensed over­voltage protection.
The primary sensed OVP protection circuit shown in Figures 41, 42 and 43 is triggered by a significant rise in output voltage (and therefore bias winding voltage). If the power supply is operating under heavy load or low input line conditions when an open
During a fault condition resulting from loss of feedback, output voltage will rapidly rise above the nominal voltage. The increase in output voltage will also result in an increase in the voltage at the output of the bias winding. A voltage at the output of the bias winding that exceeds of the sum of the voltage rating of the Zener diode connected from the bias winding output to the V-pin (or M-pin) and V-pin (or M-pin) voltage, will cause a current in excess of I
or IM to be injected into the V-pin
V
(or M-pin), which will trigger the OVP feature.
loop occurs, the output voltage may not rise significantly. Under these conditions, a latching shutdown will not occur until load or line conditions change. Nevertheless, the operation provides the desired protection by preventing significant rise in the output voltage when the line or load conditions do change. Primary side OVP protection with the TOPSwitch-HX in a typical application will prevent a nominal 12 V output from rising above approximately 20 V under open loop conditions. If greater accuracy is required, a secondary sensed OVP circuit is recommended.
I
PI-4646-071708
12
Rev. J 08/16
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TOP252-262
Line Feed-Forward with DC
Reduction
MAX
The same resistor used for UV and OV also implements line voltage feed-forward, which minimizes output line ripple and reduces power supply output sensitivity to line transients. Note that for the same CONTROL pin current, higher line voltage results in smaller operating duty cycle. As an added feature, the maximum duty cycle DC
is also reduced from 78% (typical) at a voltage slightly
MAX
lower than the UV threshold to 36% (typical) at the OV threshold. DC
of 36% at high line was chosen to ensure that the power
MAX
capability of the TOPSwitch-HX is not restricted by this feature under normal operation. TOPSwitch-HX provides a better fit to the ideal feed-forward by using two reduction slopes: -1% per mA for all bus voltage less than 195 V (typical for 4 MW line impedance) and
-0.25% per mA for all bus voltage more than 195 V. This dual slope line feed-forward improves the line ripple rejection significantly compared with the TOPSwitch-GX.
Remote ON/OFF
TOPSwitch-HX can be turned on or off by controlling the current into the VOLTAGE-MONITOR pin or out from the EXTERNAL CURRENT LIMIT pin (Y, E/L and M packages) and into or out from the MULTI-FUNCTION pin (P and G package, see Figure 12). In addition, the VOLTAGE-MONITOR pin has a 1 V threshold comparator connected at its input. This voltage threshold can also be used to perform remote ON/OFF control.
When a signal is received at the VOLTAGE-MONITOR pin or the EXTERNAL CURRENT LIMIT pin (Y, E/L and M packages) or the MULTI-FUNCTION pin (P and G package) to disable the output through any of the pin functions such as OV, UV and remote ON/OFF, TOPSwitch-HX always completes its current switching cycle before the output is forced off.
As seen above, the remote ON/OFF feature can also be used as a standby or power switch to turn off the TOPSwitch-HX and keep it in a very low power consumption state for indefinitely long periods. If the TOPSwitch-HX is held in remote off state for long enough time to allow the CONTROL pin to discharge to the internal supply undervoltage threshold of 4.8 V (approximately 32 ms for a 47
mF CONTROL pin capacitance), the CONTROL pin goes into the hysteretic mode of regulation. In this mode, the CONTROL pin goes through alternate charge and discharge cycles between 4.8 V and 5.8 V (see CONTROL pin operation section above) and runs entirely off the high voltage DC input, but with very low power consumption (160 mW typical at 230 VAC with M or X pins open). When the TOPSwitch-HX is remotely turned on after entering this mode, it will initiate a normal start-up sequence with soft-start the next time the CONTROL pin reaches 5.8 V. In the worst case, the delay from remote on to start-up can be equal to the full discharge/charge cycle time of the CONTROL pin, which is approximately 125 ms for a 47
mF CONTROL pin capacitor. This reduced consumption remote off mode can eliminate expensive and unreliable in-line mechanical switches. It also allows for microprocessor controlled turn-on and turn-off sequences that may be required in certain applications such as inkjet and laser printers.
Soft-Start
The 17 ms soft-start sweeps the peak drain current and switching frequency linearly from minimum to maximum value by operating through the low frequency PWM mode and the variable frequency mode before entering the full frequency mode. In addition to start-up, soft-start is also activated at each restart attempt during auto-restart and when restarting after being in hysteretic regulation of CONTROL pin voltage (V
), due
C
to remote OFF or thermal shutdown conditions. This effectively minimizes current and voltage stresses on the output MOSFET, the clamp circuit and the output rectifier during start-up. This feature also helps minimize output overshoot and prevents saturation of the transformer during start-up.
Shutdown/Auto-Restart
To minimize TOPSwitch-HX power dissipation under fault conditions, the shutdown/auto-restart circuit turns the power supply on and off at an auto-restart duty cycle of typically 2% if an out of regulation condition persists. Loss of regulation interrupts the external current into the CONTROL pin. V
C
regulation changes from shunt mode to the hysteretic auto­restart mode as described in CONTROL pin operation section. When the fault condition is removed, the power supply output becomes regulated, V
regulation returns to shunt mode, and
C
normal operation of the power supply resumes.
Hysteretic Over-Temperature Protection
Temperature protection is provided by a precision analog circuit that turns the output MOSFET off when the junction temperature exceeds the thermal shutdown temperature (142 °C typical). When the junction temperature cools to below the lower hysteretic temperature point, normal operation resumes, thus providing automatic recovery. A large hysteresis of 75 °C (typical) is provided to prevent overheating of the PC board due to a continuous fault condition. V
is regulated in hysteretic
C
mode, and a 4.8 V to 5.8 V (typical) triangular waveform is present on the CONTROL pin while in thermal shutdown.
Bandgap Reference
All critical TOPSwitch-HX internal voltages are derived from a temperature-compensated bandgap reference. This voltage reference is used to generate all other internal current references, which are trimmed to accurately set the switching frequency, MOSFET gate drive current, current limit, and the line OV/UV/OVP thresholds. TOPSwitch-HX has improved circuitry to maintain all of the above critical parameters within very tight absolute and temperature tolerances.
High-Voltage Bias Current Source
This high-voltage current source biases TOPSwitch-HX from the DRAIN pin and charges the CONTROL pin external capacitance during start-up or hysteretic operation. Hysteretic operation occurs during auto-restart, remote OFF and over-temperature shutdown. In this mode of operation, the current source is switched on and off, with an effective duty cycle of approxi­mately 35%. This duty cycle is determined by the ratio of CONTROL pin charge (I
) and discharge currents (I
C
CD1
and I
CD2
). This current source is turned off during normal operation when the output MOSFET is switching. The effect of the current source switching will be seen on the DRAIN voltage waveform as small disturbances and is normal.
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13
Rev. J 08/16
TOP252-262
CONTROL (C)
EXTERNAL CURRENT LIMIT (X)
Y, E/L and M Package
200 µA
VBG + V
TOPSwitch-HX
(Negative Current Sense - ON/OFF,
Current Limit Adjustment)
T
VOLTAGE MONITOR (V)
V
REF
400 µA
Figure 13a. VOLTAGE MONITOR (V) and EXTERNAL CURRENT LIMIT (X) Pin Input Simplified Schematic.
P and G Package
CONTROL (C)
MULTI-FUNCTION (M)
200 µA
VBG + V
(Negative Current Sense - ON/OFF,
T
V
REF
TOPSwitch-HX
Current Limit Adjustment)
(Positive Current Sense - Undervoltage,
Overvoltage, Maximum Duty Cycle Reduction,
Output Overvoltage Protection)
(Voltage Sense)
1 V
(Positive Current Sense - Undervoltage,
Overvoltage, ON/OFF, Maximum Duty
Cycle Reduction, Output Over-
voltage Protection)
PI-4714-071408
Figure 13b. MULTI-FUNCTION (M) Pin Input Simplified Schematic.
14
Rev. J 08/16
400 µA
PI-4715-071408
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Typical Uses of FREQUENCY (F) Pin
TOP252-262
+
DC
Input
Voltage
D
S
CONTROL
C
F
-
PI-2654-071700
Figure 14. Full Frequency Operation (132 kHz). Figure 15. Half Frequency Operation (66 kHz).
+
DC
Input
Voltage
-
D
CONTROL
S
C
F
PI-2655-071700
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