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TOP264-271 TOPSwitch-JX Family
(R)
Integrated Off-Line Switcher with EcoSmart Technology for Highly Efficient Power Supplies
(R)
Product Highlights
EcoSmart (R) - Energy Efficient * Energy efficient over entire load range * No-load consumption below 100 mW at 265 VAC * Up to 750 mW standby output power for 1 W input at 230 VAC High Design Flexibility for Low System Cost * Multi-mode PWM control maximizes efficiency at all loads * 132 kHz operation reduces transformer and power supply size * 66 kHz option for highest efficiency requirements * Accurate programmable current limit * Optimized line feed-forward for line ripple rejection * Frequency jittering reduces EMI filter cost * Fully integrated soft-start for minimum startup stress * 725 V rated MOSFET * Simplifies meeting design derating requirements Extensive Protection Features * Auto-restart limits power delivery to <3% during overload faults * Output short-circuit protection (SCP) * Output over-current protection (OCP) * Output overload protection (OPP) * Output overvoltage protection (OVP) * User programmable for hysteretic/latching shutdown * Simple fast AC reset * Primary or secondary sensed * Line undervoltage (UV) detection prevents turn-off glitches * Line overvoltage (OV) shutdown extends line surge withstand * Accurate thermal shutdown with large hysteresis (OTP) Advanced Package Options * eDIPTM-12 package: * Low profile horizontal orientation for ultra-slim designs Output Power Table
Product5 TOP264VG TOP265VG TOP266VG TOP267VG TOP268VG TOP269VG TOP270VG TOP271VG PCB Copper Area1 230 VAC 15%4 85-265 VAC Open Open 2 Adapter Adapter2 Frame3 Frame3 21 W 34 W 12 W 22.5 W 22.5 W 36 W 15 W 25 W 24 W 39 W 17 W 28.5 W 27.5 W 44 W 19 W 32 W 30 W 48 W 21.5 W 36 W 32 W 51 W 22.5 W 37.5 W 34 W 55 W 24.5 W 41 W 36 W 59 W 26 W 43 W Product5 TOP264EG/VG TOP265EG/VG TOP266EG/VG TOP267EG/VG TOP268EG/VG TOP269EG/VG TOP270EG/VG TOP271EG/VG Metal Heat Sink1 230 VAC 15% 4 85-265 VAC Open Open 2 Adapter Adapter2 Frame3 Frame3 30 W 62 W 20 W 43 W 40 W 81 W 26 W 57 W 60 W 119 W 40 W 86 W 85 W 137 W 55 W 103 W 105 W 148 W 70 W 112 W 128 W 162 W 80 W 120 W 147 W 190 W 93 W 140 W 177 W 244 W 118 W 177 W
AC IN
+ DC OUT -
D
V
CONTROL
TOPSwitch-JX
S X F
C
PI-5578-090309
Figure 1.
Typical Flyback Application.
*
* *
Heat transfer to both PCB and heat sink Optional external heat sink provides thermal impedance equivalent to a TO-220 eSIP(R)-7C package: * Vertical orientation for minimum PCB footprint * Simple heat sink mounting using clip provides thermal impedance equivalent to a TO-220 Extended creepage to DRAIN pin Heat sink is connected to SOURCE for low EMI
* *
Description
TOPSwitch-JX cost effectively incorporates a 725 V power MOSFET, high voltage switched current source, multi-mode PWM control, oscillator, thermal shutdown circuit, fault protection and other control circuitry onto a monolithic device.
Table 1. Output Power Table. Notes: 1. See Key Application Considerations section for more details. 2. Minimum continuous power in a typical non-ventilated enclosed adapter measured at +50 C ambient temperature. 3. Minimum continuous power in an open frame design at +50 C ambient temperature. 4. 230 VAC or 110/115 VAC with doubler. 5. Packages: E: eSIP-7C, V: eDIP-12. See Part Ordering Information section. www.powerint.com March 2010
TOP264-271
Section List
Functional Block Diagram ....................................................................................................................................... 3 Pin Functional Description ...................................................................................................................................... 3 TOP264-271 Functional Description ........................................................................................................................ 4 CONTROL (C) Pin Operation .................................................................................................................................... 5 Oscillator and Switching Frequency.......................................................................................................................... 5 Pulse Width Modulator ............................................................................................................................................ 5 Maximum Duty Cycle ............................................................................................................................................... 6 Error Amplifier .......................................................................................................................................................... 6 On-Chip Current Limit with External Programmability ............................................................................................... 6 Line Undervoltage Detection (UV) ............................................................................................................................. 6 Line Overvoltage Shutdown (OV) .............................................................................................................................. 7 Hysteretic or Latching Output Overvoltage Protection (OVP)..................................................................................... 7 Line Feed-Forward with DCMAX Reduction ................................................................................................................ 8 Remote ON/OFF ..................................................................................................................................................... 8 Soft-Start ................................................................................................................................................................. 9 Shutdown/Auto-Restart (for OCP, SCP, OPP) ......................................................................................................... 10 Hysteretic Over-Temperature Protection (OTP) ....................................................................................................... 10 Bandgap Reference ............................................................................................................................................... 10 High-Voltage Bias Current Source .......................................................................................................................... 10 Typical Uses of FREQUENCY (F) Pin ...................................................................................................................... 12 Typical Uses of VOLTAGE MONITOR (V) and EXTERNAL CURRENT LIMIT (X) Pins .......................................... 13 Application Examples .............................................................................................................................................. 15 Low No-load, High Efficiency, 65 W, Universal Input Adapter Power Supply ..................................................................... 15
Very low No-load, High Efficiency, 30 W, Universal Input, Open Frame, Power Supply .............................................................. 17
Key Application Considerations .............................................................................................................................. 18 TOPSwitch-JX vs.TOPSwitch-HX ........................................................................................................................ . 18 TOP264-271 Design Considerations ..................................................................................................................... 18 TOP264-271 Layout Considerations ...................................................................................................................... 20 Quick Design Checklist .......................................................................................................................................... 21 Design Tools .......................................................................................................................................................... 21 Product Specifications and Test Conditions .......................................................................................................... 23 Typical Performance Characteristics .................................................................................................................... 30 Package Outlines .................................................................................................................................................... 34 Part Ordering Information ........................................................................................................................................ 35
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TOP264-271
CONTROL (C)
ZC
VC
0
DRAIN (D) INTERNAL SUPPLY
-
1
SHUNT REGULATOR/ ERROR AMPLIFIER
+
+
5.8 V 4.8 V
-
SOFT START KPS(UPPER)
+
5.8 V
VI (LIMIT)
IFB CURRENT LIMIT ADJUST
INTERNAL UV COMPARATOR
+
ON/OFF
/ 16 SHUTDOWN/ AUTO-RESTART STOP LOGIC
KPS(LOWER)
+
EXTERNAL CURRENT LIMIT (X) VOLTAGE MONITOR (V)
VBG + VT
CURRENT LIMIT COMPARATOR SOURCE (S) CONTROLLED TURN-ON GATE DRIVER
1V V LINE SENSE OVP OV/ UV DCMAX DCMAX
HYSTERETIC THERMAL SHUTDOWN STOP SOFT START DMAX CLOCK S R Q
OSCILLATOR WITH JITTER 66k/132k F REDUCTION
FREQUENCY (F)
LEADING EDGE BLANKING
F REDUCTION SOFT START IFB PWM IPS(UPPER) IPS(LOWER) OFF
KPS(UPPER) KPS(LOWER)
PI-4511-012810
SOURCE (S)
Figure 2.
Functional Block Diagram (E and V Package).
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: Input pin for external current limit adjustment remote ON/OFF and device reset. A connection to SOURCE pin disables all functions on this pin. VOLTAGE MONITOR (V) Pin: Input for OV, UV, line feed forward with DCMAX reduction, output overvoltage protection (OVP), remote ON/OFF. A connection to the SOURCE pin disables all functions on this pin. FREQUENCY (F) Pin: Input pin for selecting switching frequency 132 kHz if connected to SOURCE pin and 66 kHz if connected to CONTROL pin.
SOURCE (S) Pin: Output MOSFET source connection for high voltage power return. Primary side control circuit common and reference point. NO CONNECTION (NC) Pin: Internally not connected, floating potential pin.
E Package (eSIP-7C)
V Package (eDIP-12)
S 12
Exposed Pad S 11 (Hidden) S 10 Internally Connected to S 9 SOURCE Pin
1V 2X 3C 4F 5 NC 6D
S8 S7
12345 7 VXCF S D
PI-5568-083109
Figure 3.
Pin Configuration (Top View).
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TOP264-271
PI-5579-012210
+
RLS 4 M
VUV = IUV x RLS + VV (IV = IUV) VOV = IOV x RLS + VV (IV = IOV) For RLS = 4 M
Auto-Restart 78 Duty Cycle (%) Slope = PWM Gain
VUV = 102.8 VDC VOV = 451 VDC
DCMAX@100 VDC = 76% DCMAX@375 VDC = 41%
C
DC Input Voltage
D
V
CONTROL
S
X RIL 12 k
For RIL = 12 k ILIMIT = 61% See Figure 35 for other resistor values (RIL) to select different ILIMIT values.
Figure 4.
CONTROL Current
Package Line Sense and Externally Set Current Limit.
TOP264-271 Functional Description
Like TOPSwitch-HX, TOP264-271 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 5. 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 TOP264-271 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 have been used to implement some of the new functions. These terminals can be connected to the SOURCE pin to operate the TOP264-271 in a TOPSwitchlike three terminal mode. However, even in this three terminal mode, the TOP264-271 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 (DCMAX) of 78% allows smaller input 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. 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.
Drain Peak Current To Current Limit Ratio (%)
100
55
25 CONTROL Current Full Frequency Mode 132 Low Frequency Mode
Frequency (kHz)
66 Jitter 30 ICD1 IB IC01
Variable Frequency Mode
Multi-Cycle Modulation
IC02
IC03 ICOFF CONTROL Current
PI-5665-110609
Figure 5.
Control Pin Characteristics (Multi-Mode Operation).
6. Hysteretic over-temperature shutdown ensures thermal fault protection. 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 DCMAX reduction. In this mode, the value of the resistor determines the OV/UV thresholds and the DCMAX is reduced linearly with a dual slope to improve line ripple rejection. In addition, it also provides another threshold to implement the latched and
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TOP264-271
hysteretic output overvoltage protection (OVP). The pin can also be used as a remote ON/OFF using the IUV threshold. 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. The FREQUENCY (F) pin sets 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. 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 VC is the supply voltage for the control circuitry including the 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 VC reaches 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 2. 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 ZC that sets the gain of the error amplifier when used in a primary feedback configuration. The dynamic impedance ZC of the 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 VC within a window of typically 4.8 V to 5.8 V by turning the high-voltage current source on and off as shown in Figure 7. 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 TOP264-271 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, when shorted to the CONTROL pin, lowers the full switching frequency to 66 kHz (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. 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 6. 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 5). 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 5 is maintained through all three PWM
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TOP264-271
Maximum Duty Cycle The maximum duty cycle, DCMAX, is set at a default maximum value of 78% (typical). However, by connecting the VOLTAGEMONITOR 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 ZC sets the gain of the error amplifier. The CONTROL pin clamps external circuit signals to the VC voltage level. The CONTROL pin current in excess of the supply current is separated by the shunt regulator and becomes the feedback current IFB for the pulse width modulator. 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 VDS(ON) with a threshold voltage. High drain current causes VDS(ON) to exceed the threshold voltage and turns 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 RDS(ON) of the output MOSFET. The default current limit of TOP264-271 is preset internally. However, with a resistor connected between EXTERNAL CURRENT LIMIT (X) pin and SOURCE 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 TOP264-271 than necessary for the power required can be used to take advantage of the lower RDS(ON) for higher efficiency/ smaller heat sinking requirements. With a second resistor connected between the EXTERNAL CURRENT LIMIT (X) pin 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. The leading edge blanking circuit inhibits the current limit comparator for a short time after the output MOSFET is turned 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. Line Undervoltage Detection (UV) At power up, UV keeps TOP264-271 off until the input line voltage reaches the undervoltage threshold. At power down,
PI-4530-041107
fOSC + Switching Frequency fOSC -
4 ms
VDRAIN Time Figure 6. Switching Frequency Jitter (Idealized VDRAIN Waveforms).
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 (IC) reaches IB. In this mode, the average switching frequency is kept constant at fOSC (pin selectable 132 kHz or 66 kHz). Duty cycle is reduced from DCMAX through the reduction of the on-time when IC is increased beyond IB. This operation is identical to the PWM control of all other TOPSwitch families. TOP264-271 only operates in this mode if the cycle-by-cycle peak drain current stays above kPS(UPPER) x ILIMIT(set), where kPS(UPPER) is 55% (typical) and ILIMIT(set) is the current limit externally set via the X pin. Variable Frequency PWM mode: When peak drain current is lowered to kPS(UPPER) x ILIMIT(set) as a result of power supply load 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 kPS(UPPER) x ILIMIT(set) while switching frequency drops from the initial full frequency of fOSC (132 kHz or 66 kHz) towards the minimum frequency of fMCM(MIN) (30 kHz typical). Duty cycle reduction is accomplished by extending the off-time. Low Frequency PWM mode: When switching frequency reaches fMCM(MIN) (30 kHz typical), the PWM modulator starts to transition to low frequency mode. In this mode, switching frequency is held constant at fMCM(MIN) and duty cycle is reduced, similar to the full frequency PWM mode, through the reduction of the on-time. Peak drain current decreases from the initial value of kPS(UPPER) x ILIMIT(set) towards the minimum value of kPS(LOWER) x ILIMIT(set), where kPS(LOWER) is 25% (typical) and ILIMIT(set) is the current limit externally set via the X pin. Multi-Cycle-Modulation mode: When peak drain current is lowered to kPS(LOWER) x 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 TMCM(MIN) at the switching frequency of fMCM(MIN) (4 or 5 consecutive pulses at 30 kHz) with the peak drain current of kPS(LOWER) x ILIMIT(set), and stays off until the CONTROL pin current falls below IC(OFF). This 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.
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TOP264-271
~ ~
~ ~
VUV
~ ~
~ ~
~ ~
VLINE 0V
S15 S14
S13 S12
S0
S15 S14
S13
S12
S0
S15
S14
S13
S12
S0
S15
S15
VC 0V
5.8 V 4.8 V
~ ~
~ ~
~ ~
~ ~
~ ~
VDRAIN
0V
~ ~
VOUT 0V
~ ~
~ ~
~ ~
1
2
3
2
4
PI-4531-121206
Note: S0 through S15 are the output states of the auto-restart counter Figure 7. Typical Waveforms for (1) Power Up (2) Normal Operation (3) Auto-Restart (4) 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 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 7). The UV feature can be disabled independent of the OV feature. Line Overvoltage Shutdown (OV) The same resistor used for UV also sets an overvoltage threshold, which, once exceeded, will force TOP264-271 to stop switching instantaneously (after completion of the current switching cycle). If this condition lasts for at least 100 ms, the TOP264-271 output will be forced into off state. When the line voltage is back to normal with a small amount of hysteresis provided on the OV threshold to prevent noise triggering, the state machine sets to S13 and forces TOP264-271 to go through the entire auto-restart sequence before attempting to switch again. The ratio of OV and UV thresholds is preset at 4.5, as can be seen in Figure 8. When the MOSFET is off, the rectified DC high voltage surge capability is increased to the voltage rating of the MOSFET (725 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.
In order to reduce the no-load input power of TOP264-271 designs, the V pin 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, 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 misoperaton of the V pin related functions. 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 voltage will drop by 0.5 V, and the controller measures the external attached impedance immediately after this voltage drops. If IV exceeds IOV(LS) (336 mA typical) longer than 100 ms, TOP264-271 will latch into a permanent off state for the latching OVP. It only can be reset if IX exceeds IX(TH) = -27 mA (typ) or VC goes below the power-up-reset threshold (VC(RESET)) and then back to normal. If IV does not exceed IOV(LS) or exceeds no longer than 100 ms, TOP264-271 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. 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 and V pin voltage, will cause a current in excess of IV to be injected into the V pin, which will trigger the OVP feature.
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TOP264-271
If the power supply is operating under heavy load or low input line conditions when an open 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 TOP264-271 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. Line Feed-Forward with DCMAX Reduction 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 DCMAX is also reduced from 78% (typical) at a voltage slightly lower than the UV threshold to 36% (typical) at the OV threshold. DCMAX of 36% at high line was chosen to ensure that the power capability of the TOP264-271 is not restricted by this feature under normal operation. TOP264-271 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. Remote ON/OFF TOP264-271 can be turned on or off by controlling the current into the VOLTAGE-MONITOR pin or out from the EXTERNAL CURRENT LIMIT pin. 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 to disable the output through any of the pin functions such as OV, UV and remote ON/OFF, TOP264-271 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 TOP264-271 and keep it in a very low power consumption state for indefinitely long periods. If the TOP264-271 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
Voltage Monitor and External Current Limit Pin Table*
Figure Number Three Terminal Operation Line Undervoltage (UV) Line Overvoltage (OV) Line Feed-Forward (DCMAX) Output Overvoltage Protection (OVP) Overload Power Limiting (OPP) External Current Limit Remote ON/OFF Device Reset Fast AC Reset AC Brownout *This table is only a partial list of many VOLTAGE MONITOR and EXTERNAL CURRENT LIMIT Pin Configurations that are possible.
Table 2. VOLTAGE MONITOR (V) Pin and EXTERNAL CURRENT LIMIT (X) Pin Configuration Options.
12
13
14
15
16
17
18
19
20
21
22
23
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 3
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TOP264-271
X Pin IREM(N) (Enabled) Output MOSFET Switching IUV
V Pin IOV IOV(LS)
(Non-Latching) (Disabled) Disabled when supply output goes out of regulation ILIMIT (Default)
(Latching)
I
Current Limit I DCMAX (78%) Maximum Duty Cycle I
VBG Pin Voltage -250 -200 -150 -100 -50 0 25 50 75 100 125 336 I
X and V Pins Current (A)
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 8. VOLTAGE MONITOR and EXTERNAL CURRENT LIMIT (E and V package) Pin Characteristics.
PI-5528-060409
section above) and runs entirely off the high voltage DC input, but with very low power consumption (<100 mW typical at 230 VAC with X pin open). When the TOP264-271 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 (VC), due 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.
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Shutdown/Auto-Restart (for OCP, SCP, OPP) To minimize TOP264-271 power dissipation under fault conditions such as over current (OC), short circuit (SC) or over power (OP), 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. VC 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, VC regulation returns to shunt mode, and normal operation of the power supply resumes. Hysteretic Over-Temperature Protection (OTP) 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. VC is regulated in hysteretic 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 TOP264-271 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. TOP264-271 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 TOP264-271 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 (IC) and discharge currents (ICD1 and ICD2). 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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TOP264-271
CONTROL (C) 200 A
(Negative Current Sense - ON/OFF, Current Limit Adjustment, OVP Latch Reset) VBG + VT EXTERNAL CURRENT LIMIT (X) VOLTAGE MONITOR (V) VREF 1V (Positive Current Sense - Undervoltage, Overvoltage, ON/OFF, Maximum Duty Cycle Reduction, Output Overvoltage Protection) 400 A
PI-5567-030910
(Voltage Sense, ON/OFF)
Figure 9.
VOLTAGE MONITOR (V) and EXTERNAL CURRENT LIMIT (X) Pin Input Simplified Schematic.
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TOP264-271
Typical Uses of FREQUENCY (F) Pin
+
+
DC Input Voltage
D
CONTROL
C
DC Input Voltage
D
CONTROL
C
S
F
S
F
PI-2654-071700
PI-2655-071700
Figure 10. Full Frequency Operation (132 kHz).
Figure 11. Half Frequency Operation (66 kHz).
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TOP264-271
Typical Uses of VOLTAGE MONITOR (V) and EXTERNAL CURRENT LIMIT (X) Pins
+
S 12 S 11 S 10 S9 S8 S7
V Package (eDIP-12)
1V 2X 3C 4F 5 NC 6D S DC
E Package (eSIP-7C)
+
VUV = IUV x RLS + VV (IV = IUV) VOV = IOV x RLS + VV (IV = IOV) RLS 4 M For RLS = 4 M VUV = 102.8 VDC VOV = 451 VDC DCMAX@100 VDC = 76% DCMAX@375 VDC = 41%
D V
CONTROL
DC Input Voltage
D
VXC FS
D
DC Input Voltage
V
CONTROL
C
SD
C
C
-
S
X
F
PI-5562-082809
-
S
PI-4717-120307
Figure 12. Three Terminal Operation (VOLTAGE MONITOR and EXTERNAL CURRENT LIMIT Features Disabled. FREQUENCY Pin Tied to SOURCE or CONTROL Pin.)
Figure 13. Line-Sensing for Undervoltage, Overvoltage and Line Feed-Forward.
+
VUV = IUV x RLS + VV (IV = IUV) VOV = IOV x RLS + VV (IV = IOV) For RLS = 4 M VUV = 102.8 VDC VOV = 451 VDC Sense Output Voltage
+
4 M
VUV = RLS x IUV + VV (IV = IUV) For Values Shown VUV = 103.8 VDC RLS
RLS DC Input Voltage
D
4 M VROVP
ROVP
DCMAX @ 100 VDC = 76% DCMAX @ 375 VDC = 41%
DC Input Voltage
D
40 k
V
CONTROL
V
CONTROL
C
ROVP >3k
6.2 V
C
-
S
PI-4719-120307
-
S
PI-4720-120307
Figure 14. Line-Sensing for Undervoltage, Overvoltage, Line Feed-Forward and Hysteretic Output Overvoltage Protection.
Figure 15. Line Sensing for Undervoltage Only (Overvoltage Disabled).
+
RLS DC Input Voltage
D
VOV = IOV x RLS + VV (IV = IOV) 4 M For Values Shown VOV = 457.2 VDC
+
For RIL = 12 k ILIMIT = 61% For RIL = 19 k ILIMIT = 37%
55 k
V
CONTROL
1N4148
C
DC Input Voltage
D
CONTROL
See Figure 35 for other resistor values (RIL).
C
S
X RIL
-
S
PI-4721-120307
Figure 17. External Set Current Limit.
PI-5580-012210
Figure 16. Line-Sensing for Overvoltage Only (Undervoltage Disabled). Maximum Duty Cycle Reduced at Low Line and Further Reduction with Increasing Line Voltage.
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Typical Uses of VOLTAGE MONITOR (V) and EXTERNAL CURRENT LIMIT (X) Pins (cont.)
+
RLS 2.5 M
ILIMIT = 100% @ 100 VDC ILIMIT = 53% @ 300 VDC
+
QR can be an optocoupler output or can be replaced by a manual switch.
DC Input Voltage
D
CONTROL
DC Input Voltage
C
D
CONTROL
C
S
X RIL 6 k
PI-5465-061009
S
X QR ON/OFF 47 K
PI-5466-061009
-
-
Figure 18. Current Limit Reduction with Line Voltage.
Figure 19. Active-on (Fail Safe) Remote ON/OFF, and Latch Reset.
+
QR can be an optocoupler output or can be replaced by a manual switch. For RIL = 12 k
+
RLS
VUV = IUV x RLS + VV (IV = IUV) VOV = IOV x RLS + VV (IV = IoV)
4 M DCMAX@100 VDC = 76% DCMAX@375 VDC = 41%
DC Input Voltage
ILIMIT = 61%
D
CONTROL
For RIL = 19 k
C
ILIMIT = 37%
DC Input Voltage
D
V
CONTROL
QR can be an optocoupler output or can be replaced by a manual switch.
C
S
X
For RIL = 12 k ILIMIT = 61%
S
X
RIL
-
QR
16 k
ON/OFF
PI-5531-072309
RIL
-
QR 16 k
ON/OFF
PI-5467-061009
Figure 20. Active-on Remote ON/OFF with Externally Set Current Limit, and Latch Reset
Figure 21. Active-on Remote ON/OFF with Line Sense and External Current Limit, and Latch Reset.
PI-5565-012210
+
RLS DC Input Voltage 4 M
VUV = IUV x RLS + VV (IV = IUV) VOV = IOV x RLS + VV (IV = IoV) For RLS = 4 M VUV = 102.8 VDC VOV = 451 VDC DCMAX @ 100 VDC = 76% DCMAX @ 375 VDC = 41%
C
+
Typ. 65 VAC brownout threshold. <3 s AC latch reset time. Higher gain QR allows increasing R1/ decreasing C1 for lower no-load input power.
D
CONTROL
D
V
CONTROL
DC Input Voltage
S
C
S
X
For RIL = 12 k ILIMIT = 61% See Figure 35 for other resistor values (RIL) to select different ILIMIT values.
X
RIL
QR
R1 4 M 1N4007 R2 39 k AC C1 Input 47 nF
PI-5652-110609
-
RIL 12 k
-
Figure 22. Line Sensing and Externally Set Current Limit.
Figure 23. Externally Set Current Limit, Fast AC Latch Reset and Brownout.
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TOP264-271
Application Example
Low No-load, High Efficiency, 65 W, Universal Input Adapter Power Supply The circuit shown in Figure 24 shows a 90 VAC to 265 VAC input, 19 V, 3.42 A output power supply, designed for operation inside a sealed adapter case type. The goals of the design were highest full load efficiency, highest average efficiency (average of 25%, 50%, 75% and 100% load points), and very low no-load consumption. Additional requirements included latching output overvoltage shutdown and compliance to safety agency limited power source (LPS) limits. Measured efficiency and no-load performance is summarized in the table shown in the schematic which easily exceed current energy efficiency requirements. In order to meet these design goals the following key design decisions were made. PI Part Selection * One device size larger selected than required for power delivery to increase efficiency The current limit programming feature of TOPSwitch-JX allows the selection of a larger device than needed for power delivery. This gives higher full load, low line efficiency by reducing the MOSFET conduction losses (IRMS2 x RDS(ON)) but maintains the overload power, transformer and other components size as if a smaller device had been used. For this design one device size larger than required for power delivery (as recommended by the power table) was selected. This typically gives the highest efficiency. Further increases in device size often results in the same or lower efficiency due to the larger switching losses associated with a larger MOSFET. Line Sense Resistor Values * Increasing line sensing resistance from 4 MW to 10.2 MW to reduce no-load input power dissipation by 16 mW Line sensing is provided by resistors R3 and R4 and sets the line undervoltage and overvoltage thresholds. The combined value of these resistors was increased from the standard 4 MW to 10.2 MW. This reduced the resistor dissipation, and therefore contribution to no-load input power, from ~26 mW to ~10 mW. To compensate the resultant change in the UV (turn-on) threshold resistor R20 was added between the CONTROL and VOLTAGEMONITOR pins. This adds a DC current equal to ~16 mA into the V pin, requiring only 9 mA to be provided via R3 and R4 to reach the V pin UV (turn-on) threshold current of 25 mA and setting the UV threshold to 95 VDC. This technique does effectively disable the line OV feature as the resultant OV threshold is raised from ~450 VDC to ~980 VDC. However in this design there was no impact as the value of input capacitance (C2) was sufficient to allow the design to withstand differential line surges greater than 2 kV without the peak drain voltage reaching the BVDSS rating of U1. Specific guidelines and detailed calculations for the value of R20 may be found in the TOPSwitch-JX Application Note (AN-47). Clamp Configuration - RZCD vs RCD * An RZCD (Zener bleed) was selected over an RCD clamp to give higher light load efficiency and lower no-load consumption
Input Voltage (VAC) Full Power Efficiency (%) Average Efficiency (%) No-load Input Power (mW)
90 86.6
115 88.4 89.8
230 89.1 89.5 86.7 VR2 SMAJ250A R5 300 R11 300 C4 1000 pF 630 V R6 150 R28 300 1 R29 300
C11 1 nF 250 VAC T1 3 RM10 FL1
C12 1 nF R15 100 V 33 C13 C14 470 F 470 F 25 V 25 V D5 V30100C C21 10 nF 50 V RTN
57.7
59.7
19 V, 3.42 A
D1 GBU8J 600 V
FL2 5 D4 BAV21WS7-F 4
R3 5.1 M
R7 10 M
C5 2.2 nF 1 kV R24 2.2
D2 RS1K Q1 MMBT4403 D3 BAV19WS
C10 56 F 35 V
R16 20 k
R22 1.6 k C19 6.8 nF 50 V
L3 12 mH C2 120 F 400 V R4 5.1 M R8 10 M
R14 20
C15 470 pF 50 V R10 100
R1 R2 2.2 M 2.2 M C1 330 nF 275 VAC L4 200 H F1 4A L 90 - 265 VAC N
R20 191 k 1%
D V CONTROL C
C9 220 nF 25 V
R12 4.7 k VR1 ZMM5244B-7 R25 20 1/8 W R13 6.8 1/8 W C7 47 F 16 V
U3B PS25011-H-A Q2 MMBT3904
U3A PS25011-H-A
R17 147 k 1% R27 10 k
TOPSwitch-JX U1 TOP269EG
S
C16 22 nF 50 V R19 20 k C22 100 nF 50 V U2 LMV431AIMF 1%
X
F
R9 11 k 1%
C6 100 nF 50 V
R18 10 k 1%
PI-5667-030810
Figure 24. Schematic of High Efficiency 19 V, 65 W, Universal Input Flyback Supply With Low No-load.
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The clamp network is formed by VR2, C4, R5, R6, R11, R28, R29 and D2. It limits the peak drain voltage spike caused by leakage inductance to below the BVDSS rating of the internal TOPSwitch-JX MOSFET. This arrangement was selected over a standard RCD clamp to improve light load efficiency and no-load input power. In a standard RCD clamp C4 would be discharged by a parallel resistor rather than a resistor and series Zener. In an RCD clamp the resistor value is selected to limit the peak drain voltage under full load and overload conditions. However under light or no-load conditions this resistor value now causes the capacitor voltage to discharge significantly as both the leakage inductance energy and switching frequency are lower. As the capacitor has to be recharged to above the reflected output voltage each switching cycle the lower capacitor voltage represents wasted energy. It has the effect of making the clamp dissipation appear as a significant load just as if it were connected to the output of the power supply. The RZCD arrangement solves this problem by preventing the voltage across the capacitor discharging below a minimum value (defined by the voltage rating of VR2) and therefore minimizing clamp dissipation under light and no-load conditions. Resistors R6 and R28 provide damping of high frequency ringing to reduce EMI. Due to the resistance in series with VR2, limiting the peak current, standard power Zeners vs a TVS type may be used for lower cost (although a TVS type was selected due to availability of a SMD version). Diode D2 was selected to have an 800 V vs the typical 600 V rating due to its longer reverse recovery time of 500 ns. This allows some recovery of the clamp energy during the reverse recovery time of the diode improving efficiency. Multiple resistors were used in parallel to share dissipation as SMD components were used. Feedback Configuration * A Darlington connection formed together with optocoupler transistor to reduce secondary side feedback current and therefore no-load input power * Low voltage, low current voltage reference IC used on secondary side to reduce secondary side feedback current and therefore no-load input power * Bias winding voltage tuned to ~9 V at no-load, high line to reduce no-load input power Typically the feedback current into the CONTROL pin at high line is ~3 mA. This current is both sourced from the bias winding (voltage across C10) and directly from the output. Both of these represent a load on the output of the power supply. To minimize the dissipation from the bias winding under no-load conditions the number of bias winding turns and value of C10 was adjusted to give a minimum voltage across C10 of ~9 V. This is the minimum required to keep the optocoupler biased. To minimize the dissipation of the secondary side feedback circuit Q2 was added to form a Darlington connection with U3B. This reduced the feedback current on the secondary to ~1 mA. The increased loop gain (due to the hFE of the transistor) was compensated by increasing the value of R16 and the addition of R25. A standard 2.5 V TL431 voltage reference was replaced with the 1.24 V LMV431 to reduce the supply current requirement from 1 mA to 100 mA. Output Rectifier Choice * Higher current rating, low VF Schottky rectifier diode selected for output rectifier A dual 15 A, 100 V Schottky rectifier diode with a VF of 0.455 V at 5 A was selected for D5. This is a higher current rating than required to reduce resistive and forward voltage losses to improve both full load and average efficiency. The use of a 100 V Schottky was possible due to the high transformer primary to secondary turns ratio (VOR = 110 V) which was in turn possible due to the high voltage rating of the TOPSwitch-JX internal MOSFET. Increased Output Overvoltage Shutdown Sensitivity * Transistor Q1 and VR1 added to improve the output overvoltage shutdown sensitivity During an open loop condition the output and therefore bias winding voltage will rise. When this exceeds the voltage of VR1 plus a VBE voltage drop Q1 turns on and current is fed into the V pin. The addition of Q1 ensures that the current into the V pin is sufficient to exceed the latching shutdown threshold even when the output is fully loaded while the supply is operating at low line as under this condition the output voltage overshoot is relatively small Output overload power limitation is provided via the current limit programming feature of the X pin and R7, R8 and R9. Resistors R8 and R9 reduce the device current limit as a function of increasing line voltage to provide a roughly flat overload power characteristic, below the 100 VA limited power source (LPS) requirement. In order to still meet this under a single fault condition (such as open circuit of R8) the rise in the bias voltage that occurs during an overload condition is also used to trigger a latching shutdown.
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TOP264-271
Very Low No-load, High Efficiency, 30 W, Universal Input, Open Frame, Power Supply The circuit shown in Figure 25 below shows an 85 VAC to 265 VAC input, 12 V, 2.5 A output power supply. The goals of the design were highest full load efficiency, average efficiency (average of 25%, 50%, 75% and 100% load points), very low noload consumption. Additional requirements included latching output overvoltage shutdown and compliance to safety agency limited power source (LPS) limits. Actual efficiency and no-load performance is summarized in the table shown in the schematic which easily exceed current energy efficiency requirements. In order to meet these design goals the following key design decisions were made. PI part selection * Ambient of 40 C allowed one device size smaller than indicated by the power table The device selected for this design was based on the 85-265 VAC, Open Frame, PCB heat sinking column of power table (Table 1). One device size smaller was selected (TOP266V vs TOP267V) due to the ambient specification of 40 C (vs the 50C assumed in the power table) and the optimum PCB area and layout for the device heatsink. The subsequent thermal and efficiency data confirmed this choice. The maximum device temperature was 107C at full load, 40 C, 85 VAC, 47 Hz (worst case conditions) and average efficiency exceeded 83% ENERGY STAR and EuP Tier 2 requirements. Transformer Core Selection * 132 kHz switching frequency allowed the selection of smaller core for lower cost
Input Voltage (VAC) Full Load Efficiency (%) Average Efficiency (%) No-load Input Power (mW) 60.8 85 115 230 C11 1 nF 250 VAC VR1 P6KE180A C12 1 nF R17 200 V 22 C14 680 F 25 V D8,9 SB560 C7 47 F 25 V D7 BAV21WS7-F R9 10 R18 110 C18 47 nF 50 V U2B LTV817D U2A LTV817D RTN C15 680 F 25 V L2 3.3 H C16 100 F 25 V 12 V, 2.5 A
The size of the magnetic core is a function of the switching frequency. The choice of the higher switching frequency of 132 kHz allowed for the use of a smaller core size. The higher switching frequency does not negatively impact the efficiency in TOPSwitch-JX designs due its small drain to source capacitance (COSS) as compared to that of discrete MOSFETs. Line Sense Resistor Values * Increasing line sensing resistance from 4 MW to 10.2 MW to reduce no-load input power dissipation by 16 mW Line sensing is provided by resistors R1 and R2 and sets the line undervoltage and overvoltage thresholds. The combined value of these resistors was increased from the standard 4 MW to 10.2 MW. This reduced the resistor, and therefore contribution to no-load input power, from ~26 mW to ~10 mW. To compensate the resultant change in the UV threshold resistor R12 was added between the CONTROL and VOLTAGE-MONITOR pins. This adds a DC current equal to ~16 mA into the V pin, requiring only 9 mA to be provided via R1 and R2 to reach the V pin UV threshold current of 25 mA and setting the UV threshold to approximately 95 VDC. This technique does effectively disable the line OV feature as the resultant OV threshold is raised from ~450 VDC to ~980 VDC. However in this design there was no impact as the value of input capacitance (C3) was sufficient to allow the design to withstand differential line surges greater than 1 kV without the peak drain voltage reaching the BVDSS rating of U1. Specific guidelines and detailed calculations for the value of R12 may be found in the TOPSwitch-JX Application Note.
81.25 83.94 86.21 84.97 85.13 61.98 74.74
6
7,8
D1 1N4007
D2 1N4007 R1 5.1 M R3 10 M
R5 10 k 1/2 W D5 FR107
C4 4.7 nF 1 kV
4 NC NC
11,12
1
2
T1 EF25
C3 82 F 400 V
R2 5.1 M
R4 10 M D6 BAV19WS
VR3 ZMM5245B-7
R19 470 D10 LL4148 R21 86.6 k 1%
L1 14 mH D3 1N4007 C1 100 nF 275 VAC D4 1N4007 TOPSwitch-JX U1 TOP266VG
S
R12 191 k 1%
D V CONTROL C
F1 3.15 A L 85 - 264 VAC N
X
F
R15 14.3 k 1%
C9 100 nF 50 V
R16 6.8 1/8 W C10 47 F 25 V
C20 33 nF 50 V U3 LMV431A 1% R23 10 k 1%
PI-5775-030810
Figure 25. Schematic of High Efficiency 12 V, 30 W, Universal Input Flyback Supply With Very Low No-load.
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Clamp Configuration - RZCD vs RCD * An RZCD (Zener bleed) was selected over RCD to give higher light load efficiency and lower no-load consumption The clamp network is formed by VR1, C4, R5 and D5. It limits the peak drain voltage spike caused by leakage inductance to below the BVDSS rating of the internal TOPSwitch-JX MOSFET. This arrangement was selected over a standard RCD clamp to improve light load efficiency and no-load input power. In a standard RCD clamp C4 would be discharged by a parallel resistor rather than a resistor and series Zener. In an RCD clamp the resistor value of R5 is selected to limit the peak drain voltage under full load and over-load conditions. However under light or no-load conditions this resistor value now causes the capacitor voltage to discharge significantly as both the leakage inductance energy and switching frequency are lower. As the capacitor has to be recharged to above the reflected output voltage each switching cycle the lower capacitor voltage represents wasted energy. It has the effect of making the clamp dissipation appear as a significant load just as if it were connected to the output of the power supply. The RZCD arrangement solves this problem by preventing the voltage across the capacitor discharging below a minimum value (defined by the voltage rating of VR1) and therefore minimizing clamp dissipation under light and no-load conditions. Zener VR1 is shown as a high peak dissipation capable TVS however a standard lower cost Zener may also be used due to the low peak current that component experiences. In many designs a resistor value of less than 50 W may be used in series with C4 to damp out high frequency ringing and improve EMI but this was not necessary in this case. Feedback Configuration * A high CTR optocoupler was used to reduce secondary bias currents and no-load input power * Low voltage, low current voltage reference IC used on secondary side to reduce secondary side feedback current and no-load input power * Bias winding voltage tuned to ~9 V at no-load, high line to reduce no-load input power Typically the feedback current into the CONTROL pin at high line is ~3 mA. This current is both sourced from the bias winding (voltage across C10) and directly from the output. Both of these represent a load on the output of the power supply. To minimize the dissipation from the bias winding under no-load conditions the number of bias winding turns and value of C7 was adjusted to give a minimum voltage across C7 of ~9 V. This is the minimum required to keep the optocoupler biased and the output in regulation. To minimize the dissipation of the secondary side feedback circuit a high CTR (CTR of 300 - 600%) optocoupler type was used. This reduces the secondary side opto-led current from ~3 mA to <~1 mA and therefore the effective load on the output. A standard 2.5 V TL431 voltage reference was replaced with the 1.24 V LMV431 to reduce the supply current requirement of this component from 1 mA to 100 mA. Output Rectifier Choice * Use of high VOR allows the use of a 60 V Schottky diode for high efficiency and lower cost The higher BVDSS rating of the TOPSwitch-JX of 725 V (compared to 600 V or 650 V rating of typical power MOSFETs) allowed a higher transformer primary to secondary turns ratio (reflected output voltage or VOR). This reduced the output diode voltage stress and allowed the use of cheaper and more efficient 60 V (vs 80 V or 100 V) Schottky diodes. The efficiency improvement occurs due the lower forward voltage drop of the lower voltage diodes. Two parallel connected axial 5 A, 60 V Schottky rectifier diodes were selected for both low cost and high efficiency. This allowed PCB heat sinking of the diode for low cost while maintaining efficiency compared to a single higher current TO-220 packaged diode mounted on a heatsink. For this configuration the recommendation is that each diode is rated at twice the output current and that the diodes share a common cathode PCB area for heat sinking so that their temperatures track. In practice the diodes current share quite effectively as can be demonstrated by monitoring their individual temperatures. Output Inductor Post Filter Soft-Finish * Inductor L2 used to provide an output soft-finish and eliminate a capacitor To prevent output overshoot during start-up the voltage appearing across L2 is used to provide a soft-finish function. When the voltage across L2 exceeds the forward drop of U2A and D10 current flows though the optocoupler LED and provides feedback to the primary. This arrangement acts to limit the rate of rise of the output voltage until it reaches regulation and eliminates the capacitor that is typically placed across U3 to provide the same function.
Key Application Considerations
TOPSwitch-JX vs. TOPSwitch-HX Table 4 compares the features and performance differences between TOPSwitch-JX and TOPSwitch-HX. Many of the new features eliminate the need for additional discrete components. Other features increase the robustness of design, allowing cost savings in the transformer and other power components. TOP264-271 Design Considerations Power Table The data sheet power table (Table 1) represents the maximum practical continuous output power based on the following conditions: 1. 12 V output. 2. Schottky or high efficiency output diode. 3. 135 V reflected voltage (VOR) and efficiency estimates. 4. A 100 VDC minimum DC bus for 85-265 VAC and 250 VDC minimum for 230 VAC. 5. Sufficient heat sinking to keep device temperature 110 C.
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TOP264-271
TOPSwitch-HX vs. TOPSwitch-JX
Function CONTROL current IC(OFF) at 0% duty cycle TOPSwitch-HX IC(OFF) = IB + 3.4 mA (TOP256-258) IB = External bias current Not available TOPSwitch-JX IC(OFF) = IB + 1.6 mA (TOP266-268) TOPSwitch-JX Advantages
* Reduced CONTROL current * Better no-load performance (<0.1 W) * Better standby performance
eDIP-12 package
Available
* 66/132 kHz frequency option for DIP style heatsink
less designs
* Better thermal performance for increased power
capability over DIP-8 package Breakdown voltage BVDSS Min. 700 V at TJ = 25 C Min. 725 V at TJ = 25 C
* Simplifies meeting customer derating requirements
(e.g. 80%)
* Extended line surge withstand
Fast AC reset
Table 4.
3 External transistor circuits using the V pin
1 External transistor circuit using the X pin
* Saves 5 components
Comparison Between TOPSwitch-HX and TOPSwitch-JX.
6. Power levels shown in the power table for the V package device assume 6.45 cm2 of 610 g/m2 copper heat sink area in an enclosed adapter, or 19.4 cm2 in an open frame. The provided peak power depends on the current limit for the respective device. TOP264-271 Selection Selecting the optimum TOP264-271 depends upon required maximum output power, efficiency, heat sinking constraints, system requirements and cost goals. With the option to externally reduce current limit, TOP264-271 may be used for lower power applications where higher efficiency is needed or minimal heat sinking is available. Input Capacitor The input capacitor must be chosen to provide the minimum DC voltage required for the TOP264-271 converter to maintain regulation at the lowest specified input voltage and maximum output power. Since TOP264-271 has a high DCMAX limit and an optimized dual slope line feed forward for ripple rejection, it is possible to use a smaller input capacitor. For TOP264-271, a capacitance of 2 mF per watt is possible for universal input with an appropriately designed transformer. Primary Clamp and Output Reflected Voltage VOR A primary clamp is necessary to limit the peak TOP264-271 drain to source voltage. A Zener clamp requires few parts and takes up little board space. For good efficiency, the clamp Zener should be selected to be at least 1.5 times the output reflected voltage VOR, as this keeps the leakage spike conduction time short. When using a Zener clamp in a universal input application, a VOR of less than 135 V is recommended to allow for the absolute tolerances and temperature variations of the Zener. This will ensure efficient operation of the clamp circuit and will also keep the maximum drain voltage below the rated breakdown voltage of the TOP264-271 MOSFET. A high VOR is required to take full advantage of the wider DCMAX of TOP264-271. An RCD (or RCDZ) clamp provides tighter clamp voltage tolerance than a
Zener clamp and allows a VOR as high as 150 V. RCD clamp dissipation can be minimized by reducing the external current limit as a function of input line voltage (see Figure 18). The RCD clamp is more cost effective than the Zener clamp but requires more careful design (see Quick Design Checklist). Output Diode The output diode is selected for peak inverse voltage, output current, and thermal conditions in the application (including heat sinking, air circulation, etc.). The higher DCMAX of TOP264-271, along with an appropriate transformer turns ratio, can allow the use of a 80 V Schottky diode for higher efficiency on output voltages as high as 15 V. Bias Winding Capacitor Due to the low frequency operation at no-load, a bias winding capacitance of 10 mF minimum is recommended. Ensure a minimum bias winding voltage of >9 V at zero load for correct operation and output voltage regulation. Soft-Start Generally, a power supply experiences maximum stress at start-up before the feedback loop achieves regulation. For a period of 17 ms, the on-chip soft-start linearly increases the drain peak current and switching frequency from their low starting values to their respective maximum values. This causes the output voltage to rise in an orderly manner, allowing time for the feedback loop to take control of the duty cycle. This reduces the stress on the TOP264-271 MOSFET, clamp circuit and output diode(s), and helps prevent transformer saturation during start-up. Also, soft-start limits the amount of output voltage overshoot and, in many applications, eliminates the need for a soft-finish capacitor. Note that as soon as the loop closes the soft-start function ceases even if this is prior to the end of the 17 ms soft-start period. EMI The frequency jitter feature modulates the switching frequency over a narrow band as a means to reduce conducted EMI peaks associated with the harmonics of the fundamental switching 19
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Rev. B 03/10
TOP264-271
frequency. This is particularly beneficial for average detection mode. As can be seen in Figures 26 and 27, the benefits of jitter increase with the order of the switching harmonic due to an increase in frequency deviation. The FREQUENCY pin offers a switching frequency option of 132 kHz or 66 kHz. In applications that require heavy snubber on the drain node for reducing high frequency radiated noise (for example, video noise sensitive applications such as VCRs, DVDs, monitors, TVs, etc.), operating at 66 kHz will reduce snubber loss, resulting in better efficiency. Also, in applications where transformer size is not a concern, use of the 66 kHz option will provide lower EMI and higher efficiency. Note that the second harmonic of 66 kHz is still below 150 kHz, above which the conducted EMI specifications get much tighter. For 10 W or below, it is possible to use a simple inductor in place of a more costly AC input common mode choke to meet worldwide conducted EMI limits. Transformer Design It is recommended that the transformer be designed for maximum operating flux density of 3000 Gauss and a peak flux density of 4200 Gauss at maximum current limit. The turns ratio should be chosen for a reflected voltage (VOR) no greater than 135 V when using a Zener clamp or 150 V (max) when using an RCD clamp with current limit reduction with line voltage (overload protection). For designs where operating current is significantly lower than the default current limit, it is recommended to use an externally set current limit close to the operating peak current to reduce peak flux density and peak power (see Figure 17). Standby Consumption Frequency reduction can significantly reduce power loss at light or no load, especially when a Zener clamp is used. For very low secondary power consumption, use a TL431 regulator for feedback control. A typical TOP264-271 circuit automatically enters MCM mode at no load and the low frequency mode at light load, which results in extremely low losses under no-load or standby conditions. High Power Designs The TOP264-271 family contains parts that can deliver up to 162 W. High power designs need special considerations. Guidance for high power designs can be found in the Design Guide for TOP264-271 (AN-47). TOP264-271 Layout Considerations
Amplitude (dBV)
be located closely between their respective pin and SOURCE. Once again, the SOURCE connection trace of these components should not be shared by the main MOSFET switching currents. It is very critical that SOURCE pin switching currents are returned to the input capacitor negative terminal through a separate trace that is not shared by the components connected to CONTROL, VOLTAGE MONITOR or EXTERNAL CURRENT LIMIT pins. This is because the SOURCE pin is also the controller ground reference pin. Any traces to the V, X or C pins should be kept as short as possible and away from the DRAIN trace to prevent noise coupling. VOLTAGE MONITOR resistors (RLS in Figures 13, 14, 18, 21, 22, 25, 29) and primary side OVP circuit components VZOV/ROV in Figures (28, 29) should be located close to the V pin to minimize the trace length on the V pin side. Resistors connected to the V or X pin should be connected as close to the bulk cap positive terminal as possible while routing these connections away from the power switching circuitry. In addition to the 47 mF CONTROL pin capacitor, a high frequency bypass capacitor (CBP) in parallel should be used for better noise immunity. The feedback optocoupler output should also be
PI-2576-010600
80 70 60
Amplitude (dBV)
50 40 30 20 -10 0 -10 -20 0.15 1
EN55022B (QP) EN55022B (AV)
10
30
Frequency (MHz)
Figure 26. Fixed Frequency Operation Without Jitter.
PI-5583-090309
80 70 60 50 40 30 20 -10 0 -10 -20 0.15 1
EN55022B (QP) EN55022B (AV)
TOPSwitch-JX (with jitter)
The TOP264-271 has multiple pins and may operate at high power levels. The following guidelines should be carefully followed. Primary Side Connections Use a single point (Kelvin) connection at the negative terminal of the input filter capacitor for the SOURCE pin and bias winding return. This improves surge capabilities by returning surge currents from the bias winding directly to the input filter capacitor. The CONTROL pin bypass capacitor should be located as close as possible to the SOURCE and CONTROL pins, and its SOURCE connection trace should not be shared by the main MOSFET switching currents. All SOURCE pin referenced components connected to the VOLTAGE MONITOR (V pin) or EXTERNAL CURRENT LIMIT (X pin) pins should also 20
Rev. B 03/10
10
30
Frequency (MHz)
Figure 27. TOPSwitch-JX Full Range EMI Scan (132 kHz With Jitter) With Identical Circuitry and Conditions.
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TOP264-271
located close to the CONTROL and SOURCE pins of TOP264-271 and away from the drain and clamp component traces. The primary side clamp circuit should be positioned such that the loop area from the transformer end (shared with DRAIN) and the clamp capacitor is minimized. The bias winding return node should be connected via a dedicated trace directly to the bulk capacitor and not to the SOURCE pins. This ensures that surge currents are routed away from the SOURCE pins of the TOPSwitch-JX. Y Capacitor The Y capacitor should be connected close to the secondary output return pin(s) and the positive primary DC input pin of the transformer. If the Y capacitor is returned to the negative end of the input bulk capacitor (rather than the positive end) a dedicated trace must be used to make this connection. This is to "steer" leakage currents away from the SOURCE pins in case of a common-mode surge event. Heat Sinking The exposed pad of the E package (eSIP-7C) and the V package (eDIP-12) is internally electrically tied to the SOURCE pin. To avoid circulating currents, a heat sink attached to the exposed pad should not be electrically tied to any primary ground/source nodes on the PC board. On double sided boards, topside and bottom side areas connected with vias can be used to increase the effective heat sinking area. In addition, sufficient copper area should be provided at the anode and cathode leads of the output diode(s) for heat sinking. In Figure 28, a narrow trace is shown between the output rectifier and output filter capacitor. This trace acts as a thermal relief between the rectifier and filter capacitor to prevent excessive heating of the capacitor. 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 misoperaton of the V pin related functions. As with any power supply design, all TOP264-271 designs should be verified on the bench to make sure that components specifications are not exceeded under worst-case conditions. The following minimum set of tests is strongly recommended: 1. Maximum drain voltage - Verify that peak VDS does not exceed 675 V at highest input voltage and maximum overload output power. Maximum overload output power occurs when the output is overloaded to a level just before the power supply goes into auto-restart (loss of regulation). 2. Maximum drain current - At maximum ambient temperature, maximum input voltage and maximum output load, verify drain current waveforms at start-up for any signs of transformer saturation and excessive leading edge current spikes. TOP264-271 has a leading edge blanking time of 220 ns to prevent premature termination of the ON-cycle. Verify that the leading edge current spike is below the allowed current limit envelope (see Figure 32) for the drain current waveform at the end of the 220 ns blanking period. 3. Thermal check - At maximum output power, both minimum and maximum voltage and ambient temperature; verify that temperature specifications are not exceeded for TOP264271, transformer, output diodes and output capacitors. Enough thermal margin should be allowed for the part-topart variation of the RDS(ON) of TOP264-271, as specified in the data sheet. The margin required can either be calculated from the values in the parameter table or it can be accounted for by connecting an external resistance in series with the DRAIN pin and attached to the same heat sink, having a resistance value that is equal to the difference between the measured RDS(ON) of the device under test and the worst case maximum specification.
Quick Design Checklist
In order to reduce the no-load input power of TOP264-271 designs, the V pin operates at very low current. 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, 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
Design Tools
Up-to-date information on design tools can be found at the Power Integrations website: www.powerint.com
21
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Rev. B 03/10
TOP264-271
Maximize Copper Area for Optimum Heat Sinking
RLS1 RPL1 CB ROV RPL2 RLS2 DB VZOV R12 RIL CBP C10 R16 U2 U3 T1 J2
DC - OUT
+
C16
HF LC Post-Filter
U1
Output Filter Capacitors
Transformer
C18
L2 C17 D8
J1 -
Output Rectifiers
DC IN + C4
D5
R5 VR1 YCapacitor C11
D9
C3
Input Filter Capacitor
Clamp Circuit
PI-5752-012510
Figure 28. Layout Considerations for TOPSwitch-JX Using V-Package and Operating at 132 kHz.
Clamp Circuit Input Filter Capacitor
+ HV J1 HS1 C4 R6 D5 C6 R7 T1
Isolation Barrier YCapacitor C16 R12
D8 HS2 Transformer C17 RIL L3
Output Rectifier Output Filter Capacitors
CBP C RLS2
S
D F X
U1 C9
VR1
V RLS1 RPL1 ROV R8 RPL2 VZOV DB CB U4 R10 R9 JP2 U2 R15 C21 C19 R20 J2 R21 - DC + OUT C18
HF LC Post-Filter
R17 R13
PI-5793-030910
Figure 29. Layout Considerations for TOPSwitch-JX Using E-Package and Operating at 132 kHz.
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TOP264-271
Absolute Maximum Ratings(2) DRAIN Pin Peak Voltage.......................................................... -0.3 V to 725 V DRAIN Pin Peak Current: TOP264 ....................................................... 2.08 A DRAIN Pin Peak Current: TOP265 ........................................................2.72 A DRAIN Pin Peak Current: TOP266 ....................................................... 4.08 A DRAIN Pin Peak Current: TOP267........................................................ 5.44 A DRAIN Pin Peak Current: TOP268 ....................................................... 6.88 A DRAIN Pin Peak Current: TOP269 ........................................................ 7.73 A DRAIN Pin Peak Current: TOP270 ........................................................ 9.00 A DRAIN Pin Peak Current: TOP271........................................................ 11.10 A CONTROL Pin Voltage ...................................................................-0.3 V to 9 V CONTROL Pin Current ............................................................................. 100 mA VOLTAGE MONITOR Pin Voltage ............................................-0.3 V to 9 V CURRENT LIMIT Pin Voltage ................................................-0.3 V to 4.5 V Thermal Resistance Thermal Resistance: E Package (qJA) ................................................................105 C/W(1) (qJC) ............................................... .....................2 C/W(2) V Package (qJA) ........................................ 68 C/W(3), 58 C/W(4) (qJC) ............................................... .....................2 C/W(2) Notes: 1. Free standing with no heatsink. 2. Measured at the back surface of tab. 3. Soldered to 0.36 sq. in. (232 mm2), 2 oz. (610 g/m2) copper clad. 4. Soldered to 1 sq. in. (645 mm2), 2 oz. (610 g/m2) copper clad. FREQUENCY Pin Voltage ...........................................................-0.3 V to 9 V Storage Temperature ...........................................................-65 C to 150 C Operating Junction Temperature................................... -40 C to 150 C Lead Temperature(1) ......................................................................................260 C Notes: 1. 1/16 in. from case for 5 seconds. 2. Maximum ratings specified may be applied one at a time without causing permanent damage to the product. Exposure to Absolute Maximum Rating conditions for extended periods of time may affect product reliability.
Parameter
Control Functions Switching Frequency in Full Frequency Mode (average) Frequency Jitter Deviation Frequency Jitter Modulation Rate Maximum Duty Cycle Soft-Start Time
Symbol
Conditions SOURCE = 0 V; TJ = -40 to 125 C See Figure 32 (Unless Otherwise Specified)
FREQUENCY Pin Connected to SOURCE FREQUENCY Pin Connected to CONTROL 132 kHz Operation 66 kHz Operation
Min
Typ
Max
Units
fOSC Df fM DCMAX tSOFT
TJ = 25 C
119 59.4
132 66 5 2.5 250
145 72.6
kHz
kHz Hz 83
IC = ICD1
IV IV(DC) VV = 0 V IV = 95 mA TJ = 25 C TOP264-265 TOP266-268 TOP269-271 TOP264-265 TOP266-268 TOP269-271 See Note B TOP264-265
75 30
78
% ms
17 -62 -54 -50 -61 -60 -57 -50 -44 -40 -51 -50 -48 -0.01 0.8 0.9 1.0 1.4 1.5 1.6 2.0 2.1 2.2 -40 -34 -30 -41 -40 -38
TJ = 25 C IB < IC < IC01 See Note C PWM Gain DCreg TJ = 25 C IC IC01 See Note A PWM Gain Temperature Drift
%/mA
%/mA/C
External Bias Current
IB
66 kHz Operation
TOP266-268 TOP269-271
mA
23
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Rev. B 03/10
TOP264-271
Conditions SOURCE = 0 V; TJ = -40 to 125 C (Unless Otherwise Specified)
Parameter
Control Functions (cont.) External Bias Current
Symbol
Min
Typ
Max
Units
IB
132 kHz Operation
66 kHz Operation CONTROL Current at 0% Duty Cycle IC(OFF) 132 kHz Operation Dynamic Impedance Dynamic Impedance Temperature Drift CONTROL Pin Internal Filter Pole Upper Peak Current to Set Current Limit Ratio Lower Peak Current to Set Current Limit Ratio Multi-CycleModulation Switching Frequency Minimum Multi-CycleModulation On Period Shutdown/Auto-Restart CONTROL Pin Charging Current Charging Current Temperature Drift Auto-Restart Upper Threshold Voltage Auto-Restart Lower Threshold Voltage Auto-Restart Hysteresis Voltage Auto-Restart Duty Cycle Auto-Restart Frequency Line Undervoltage Threshold Current and Hysteresis (V Pin) Line Overvoltage Threshold Current and Hysteresis (V Pin) 24
Rev. B 03/10
TOP264-265 TOP266-268 TOP269-271 TOP264-265 TOP266-268 TOP269-271 TOP264-265 TOP266-268 TOP269-271
0.9 1.2 1.5
1.5 1.8 2.1 2.9 3.1 3.3 3.1 3.4 3.8 21 0.18 7
2.1 2.4 2.8 3.9 4.1 4.3 4.1 4.4 4.8 25
mA
mA
ZC
IC = 2.5 mA; TJ = 25 C, See Figure 31
13
W %/C kHz
kPS(UPPER) kPS(LOWER) fMCM(MIN) TMCM(MIN)
TJ = 25 C See Note C TJ = 25 C See Note C TJ = 25 C TJ = 25 C VC = 0 V VC = 5 V See Note B
50
55 25 30
60
% % kHz
135
ms
IC(CH)
TJ = 25 C
-5.0 -3.0
-3.5 -1.8 0.5 5.8
-1.0 -0.6
mA %/C V
VC(AR)U VC(AR)L 4.5
4.8
5.1
V
Voltage Monitor (V) and External Current Limit (X) Inputs VC(AR)hyst DC(AR) f(AR) IUV TJ = 25 C Threshold Hysteresis Threshold Hysteresis 107 22 0.8 1.0 2 0.5 25 14 112 4 117 27 4 V % Hz mA mA mA mA
IOV
TJ = 25 C
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TOP264-271
Parameter
Symbol
Conditions SOURCE = 0 V; TJ = -40 to 125 C (Unless Otherwise Specified)
Min
Typ
Max
Units
Voltage Monitor (V) and External Current Limit (X) Inputs (cont.) Output Overvoltage Latching Shutdown Threshold Current V Pin Remote ON/OFF Voltage X Pin Remote ON/OFF and Latch Reset Negative Threshold Current and Hysteresis V Pin Short Circuit Current X Pin Short Circuit Current V Pin Voltage (Positive Current) V Pin Voltage Hysteresis (Positive Current) X Pin Voltage (Negative Current) Maximum Duty Cycle Reduction Onset Threshold Current Maximum Duty Cycle Reduction Slope IOV(LS) VV(TH) TJ = 25 C TJ = 25 C Threshold IREM (N) TJ = 25 C Hysteresis IV(SC) IX(SC) VV VV(hyst) VX TJ = 25 C VX = 0 V IV = IOV VV = VC Normal Mode Auto-Restart Mode TOP264-TOP271 IV = IOV IX = -50 mA IX = -150 mA IC IB, TJ = 25 C IV(DC) < IV <48 mA IV 48 mA X or V Pin Floating ID(RMT) VDRAIN = 150 V V Pin Shorted to CONTROL 66 kHz 132 kHz 66 kHz 132 kHz 300 -260 -95 2.83 0.2 1.23 1.15 18.9 5 400 -200 -75 3.0 0.5 1.30 1.22 22.0 -1.0 %/mA -0.25 0.6 1.0 3.0 1.5 3.0 1.5 1.0 mA 1.6 ms 1.37 1.29 24.2 500 -140 -55 3.25 mA mA V V V 269 336 403 mA V
0.8 -35
1.0 -27
1.6 -20
mA
IV(DC)
mA
TJ = 25 C
Remote-OFF DRAIN Supply Current
Remote-ON Delay
tR(ON)
From Remote-ON to Drain Turn-On See Note C Minimum Time Before Drain Turn-On to Disable Cycle See Note C
Remote-OFF Set-up Time Frequency Input FREQUENCY Pin Threshold Voltage FREQUENCY Pin Input Current
tR(OFF)
ms
VF IF TJ = 25 C
See Note B VF = VC 10
2.9 55 90
V mA
25
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Rev. B 03/10
TOP264-271
Parameter
Symbol
Conditions SOURCE = 0 V; TJ = -40 to 125 C (Unless Otherwise Specified)
Min
Typ
Max
Units
Circuit Protection TOP264E/V TJ = 25 C TOP265E/V TJ = 25 C TOP266E/V TJ = 25 C Self Protection Current Limit (See Note C) ILIMIT TOP267E/V TJ = 25 C TOP268E/V TJ = 25 C TOP269E/V TJ = 25 C TOP270E/V TJ = 25 C TOP271E/V TJ = 25 C Initial Current Limit Power Coefficient Leading Edge Blanking Time Current Limit Delay Thermal Shutdown Temperature Thermal Shutdown Hysteresis Power-Up Reset Threshold Voltage VC(RESET) Figure 33 (S1 Open Condition) 1.75 IINIT PCOEFF tLEB tIL(D) 135 TJ = 25 C, See Note E di/dt = 270 mA/ms di/dt = 350 mA/ms di/dt = 530 mA/ms di/dt = 625 mA/ms di/dt = 675 mA/ms di/dt = 720 mA/ms di/dt = 870 mA/ms di/dt = 1065 mA/ms 1.209 1.581 2.371 2.800 3.023 3.236 3.906 4.808 0.70 x ILIMIT(MIN) 0.9 x I2f 0.9 x I2f I2f I2f 220 100 142 75 3.0 4.25 150 1.2 x I2f 1.2 x I2f 1.30 1.70 2.55 3.01 3.25 3.48 4.20 5.17 1.391 1.819 2.728 3.222 A 3.478 3.723 4.494 5.532 A A2kHz ns ns C C V
See Note C IX - 165 mA IX - 117 mA
TJ = 25 C, See Figure 32
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Rev. B 03/10
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TOP264-271
Parameter
Output
Symbol
Conditions SOURCE = 0 V; TJ = -40 to 125 C (Unless Otherwise Specified)
Min
Typ
Max
Units
TOP264 ID = 150 mA TOP265 ID = 200 mA TOP266 ID = 300 mA ON-State Resistance TOP267 ID = 400 mA TOP268 ID = 500 mA TOP269 ID = 600 mA TOP270 ID = 700 mA TOP271 ID = 800 mA DRAIN Supply Voltage OFF-State Drain Leakage Current Breakdown Voltage Rise Time Fall Time IDSS BVDSS tR tF
TJ = 25 C TJ = 100 C TJ = 25 C TJ = 100 C TJ = 25 C TJ = 100 C TJ = 25 C TJ = 100 C TJ = 25 C TJ = 100 C TJ = 25 C TJ = 100 C TJ = 25 C TJ = 100 C TJ = 25 C TJ = 100 C 18 36
5.4 8.35 4.1 6.3 2.8 4.1 2.0 3.1 1.7 2.5 1.45 2.25 1.20 1.80 1.05 1.55
6.25 9.70 4.70 7.30 3.20 4.75 2.30 3.60 1.95 2.90 1.70 2.60 1.40 2.10 1.20 1.80 V 470 mA V W
RDS(ON)
TJ 85 C, See Note F
VV = Floating, Device Not Switching, VDS = 580 V, TJ = 125 C VV = Floating, Device Not Switching, TJ = 25 C, See Note G Measured in a Typical Flyback Converter Application 725 100 50 0.6 0.9 1.1 0.8 1.2 1.5 0.3 1.2 1.4 1.6 1.4 1.7 2.1 0.5
ns ns 2.0 2.3 2.5 2.1 2.4 2.9 1.2 mA
Supply Voltage Characteristics Output MOSFET Enabled VX, VV = 0V 66 kHz Operation TOP264-265 TOP266-268 TOP269-271 TOP264-265 TOP266-268 TOP269-271
Control Supply/ Discharge Current
ICD1
132 kHz Operation
ICD2
Output MOSFET Disabled VX, VV = 0 V
27
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Rev. B 03/10
TOP264-271
NOTES: A. Derived during test from the parameters DCMAX, IB and IC(OFF) at 132 kHz. B. For specifications with negative values, a negative temperature coefficient corresponds to an increase in magnitude with increasing temperature, and a positive temperature coefficient corresponds to a decrease in magnitude with increasing temperature. C. Guaranteed by characterization. Not tested in production. D. For externally adjusted current limit values, please refer to Figures 34 and 35 (Current Limit vs. External Current Limit Resistance) in the Typical Performance Characteristics section. The tolerance specified is only valid at full current limit. E. I2f calculation is based on typical values of ILIMIT and fOSC, i.e. ILIMIT(TYP)2 x fOSC, where fOSC = 66 kHz or 132 kHz depending on F pin connection. See fOSC specification for detail. F. The device will start up at 18 VDC drain voltage. The capacitance of electrolytic capacitors drops significantly at temperatures below 0 C. For reliable start up at 18 V in sub zero temperatures, designers must ensure that circuit capacitors meet recommended capacitance values. G. Breakdown voltage may be checked against minimum BVDSS specification by ramping the DRAIN pin voltage up to but not exceeding minimum BVDSS.
28
Rev. B 03/10
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TOP264-271
t2
HV DRAIN VOLTAGE 0V
t1 90% t1 t2 90%
D= 10%
PI-2039-033001
PI-4737-061207
120
100 80 60 40 20 0 5 6 7 8
Dynamic 1 = Impedance Slope
1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0
tLEB (Blanking Time)
DRAIN Current (normalized)
CONTROL Pin Current (mA)
IINIT(MIN)
9
1
2
3
4
5
6
7
8
CONTROL Pin Voltage (V)
Figure 31. CONTROL Pin I-V Characteristic.
Time (s)
Figure 32. Drain Current Operating Envelope.
(X and V Pins) S1 470 5W 0-300 k
5-50 V 40 V 470 S2 0-15 V 47 F 0.1 F S4
F X S C V
CONTROL
D C
S3 0-60 k
NOTES: 1. This test circuit is not applicable for current limit or output characteristic measurements.
PI-5534-072409
Figure 33. TOPSwitch-JX General Test Circuit.
PI-4758-061407
Figure 30. Duty Cycle Measurement.
29
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Rev. B 03/10
TOP264-271
Typical Performance Characteristics
1.1 1 0.9
Maximum
PI-5581-090309
1.1 1 0.9 0.8
Normalized Current Limit
0.8 0.7 0.6 0.5 0.4
Notes: 1. Maximum and Minimum levels are based on characterization. 2. T J = 0
O
Typical
0.7 0.6
Minimum
0.5 0.4 0.3 0.2 0.1 0
Normalized Current Limit 0.3 0.2 0.1 0 -200
C to 125
O
C.
-150
-100
-50
0
I X ( A )
Figure 34. Normalized Current Limit vs. X Pin Current.
1.1 1 0.9 0.8
Maximum Notes: 1. Maximum and Minimum levels are based on characterization. 2. T J = 0 OC to 125 OC. 3. Includes the variation of X pin voltage.
PI-5582-090309
1.1 1 0.9 0.8 0.7 s)
Normalized Current Limit
0.6 0.5 0.4
Typical
0.6 0.5 0.4 0.3 0.2
0.3 Normalized Current Limit (A) 0.2 0.1 0 0 5 10 15 20 RIL ( k ) 25 30 35 40 45
Minimum
0.1 0
Figure 35. Normalized Current Limit vs. External Current Limit Resistance.
30
Rev. B 03/10
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Normalized di/dt
0.7
Normalized di/dt
t
Normalized di
TOP264-271
Typical Performance Characteristics (cont.)
1.1
PI-176B-033001
Output Frequency (Normalized to 25 C)
1.0 0.8 0.6 0.4 0.2
Breakdown Voltage (Normalized to 25 C)
1.0
0.9 -50 -25 0 25 50 75 100 125 150
0
-50 -25 0 25 50 75 100 125 150
Junction Temperature (C)
Figure 36. Breakdown Voltage vs. Temperature.
Junction Temperature (C)
Figure 37. Frequency vs. Temperature.
PI-4760-061407
Current Limit (Normalized to 25 C)
Current Limit (Normalized to 25 C)
1.0 0.8 0.6 0.4 0.2
1.0 0.8 0.6 0.4 0.2 0
0 -50 -25 0 25 50 75 100 125 150
-50 -25
Figure 39.
0
25
50
75 100 125 150
Junction Temperature (C)
Figure 38. Internal Current Limit vs. Temperature.
Junction Temperature (C)
External Current Limit vs. Temperature with RIL = 10.5 kW.
PI-4761-061407
Overvoltage Threshold (Normalized to 25 C)
1.0 0.8 0.6 0.4 0.2
Under-Voltage Threshold (Normalized to 25 C)
1.0 0.8 0.6 0.4 0.2
0 -50 -25 0 25 50 75 100 125 150
0 -50 -25 0 25 50 75 100 125 150
Junction Temperature (C)
Figure 40. Overvoltage Threshold vs. Temperature.
Junction Temperature (C)
Figure 41. Undervoltage Threshold vs. Temperature.
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Rev. B 03/10
PI-4762-061407
1.2
1.2
PI-4739-061507
1.2
1.2
PI-4759-061407
1.2
31
TOP264-271
Typical Performance Characteristics (cont.)
VOLTAGE MONITOR Pin Voltage (V)
PI-4740-060607
EXTERNAL CURRENT LIMIT Pin Voltage (V)
5.5 5 4.5 4 3.5 3 2.5 2 0 100 200 300 400
1.4 1.2 1.0 0.8 0.6 0.4 0.2
VX = 1.354 - 1147.5 x IX + 1.759 x 106 x (IX)2 with -180 A < IX < -25 A
500
0 -200
-150
-100
-50
0
VOLTAGE-MONITOR Pin Current (A)
Figure 42. VOLTAGE-MONITOR Pin vs. Current.
EXTERNAL CURRENT LIMIT Pin Current (A)
Figure 43. EXTERNAL CURRENT LIMIT Pin Voltage vs. Current.
PI-4763-072208
Onset Threshold Current (Normalized to 25 C)
CONTROL Current (Normalized to 25 C)
1.0 0.8 0.6 0.4 0.2
1.0 0.8 0.6 0.4 0.2
0 -50 -25 0 25 50 75 100 125 150
0 -50 -25 0 25 50 75 100 125 150
Junction Temperature (C)
Figure 44. Control Current Out at 0% Duty Cycle vs. Temperature.
Junction Temperature (C)
Figure 45. Maximum Duty Cycle Reduction Onset Threshold Current vs. Temperature.
PI-5569-110409
CONTROL Pin Current (mA)
DRAIN Current (A)
4 3 2 1
TCASE = 25 C TCASE = 100 C Scaling Factors: TOP271 1.62 TOP270 1.42 TOP269 1.17 TOP268 1.00 TOP267 0.85 TOP266 0.61 TOP265 0.42 TOP264 0.32
0.5 0 -0.5 -1 -1.5 -2 -2.5
VC = 5 V
0 0
2 4 6 8 10 12 14 16 18 20
0
20
40
60
80
100
Drain Voltage (V)
Figure 46. Output Characteristics.
Drain Pin Voltage (V)
Figure 47. IC vs. DRAIN Voltage.
32
Rev. B 03/10
www.powerint.com
PI-4744-072208
5
1
PI-4764-061407
1.2
1.2
PI-4741-110907
6
1.6
TOP264-271
Typical Performance Characteristics (cont.)
PI-5570-090309
DRAIN Capacitance (pF)
Power (mW)
1000
Scaling Factors: TOP271 1.62 TOP270 1.42 TOP269 1.17 TOP268 1.00 TOP267 0.85 TOP266 0.61 TOP265 0.42 TOP264 0.32
400 300
Scaling Factors: TOP271 1.62 TOP270 1.42 TOP269 1.17 TOP268 1.00 TOP267 0.85 TOP266 0.61 TOP265 0.42 TOP264 0.32
132 kHz
100
200
66 kHz
100
10
0
100
200
300
400
500
600
0 0 100 200 300 400 500 600 700
Drain Pin Voltage (V)
Figure 48. COSS vs. DRAIN Voltage.
Drain Pin Voltage (V)
Figure 49. DRAIN Capacitance Power.
Remote OFF DRAIN Supply Current (Normalized to 25 C)
1.0 0.8 0.6 0.4 0.2 0 -50 -25
0
25
50
75 100 125 150
Junction Temperature (C)
Figure 50. Remote OFF DRAIN Supply Current vs. Temperature.
PI-4745-061407
1.2
PI-5571-090309
10000
500
33
www.powerint.com
Rev. B 03/10
TOP264-271
eSIP-7C (E Package)
2 A B C
0.403 (10.24) 0.397 (10.08)
0.081 (2.06) 0.077 (1.96)
0.264 (6.70) Ref.
2
Detail A 0.290 (7.37) Ref. 0.519 (13.18) Ref. 0.140 (3.56) 0.120 (3.05) 0.070 (1.78) Ref. 0.050 (1.27)
3
0.325 (8.25) 0.320 (8.13)
0.198 (5.04) Ref.
Pin #1 I.D.
0.016 (0.41) Ref. 0.047 (1.19)
0.207 (5.26) 0.187 (4.75)
3 4
0.016 (0.41) 6x 0.011 (0.28) 0.020 M 0.51 M C
0.100 (2.54) 0.118 (3.00) SIDE VIEW
0.033 (0.84) 6x 0.028 (0.71) 0.010 M 0.25 M C A B BACK VIEW
FRONT VIEW
10 Ref. All Around 0.021 (0.53) 0.019 (0.48) 0.060 (1.52) Ref. 0.020 (0.50) PIN 1 0.048 (1.22) 0.046 (1.17) 0.019 (0.48) Ref. 0.023 (0.58) END VIEW Notes: 1. Dimensioning and tolerancing per ASME Y14.5M-1994. 2. Dimensions noted are determined at the outermost extremes of the plastic body exclusive of mold flash, tie bar burrs, gate burrs, and interlead flash, but including any mismatch between the top and bottom of the plastic body. Maximum mold protrusion is 0.010 [0.25] per side. 3. Dimensions noted are inclusive of plating thickness. 4. Does not include inter-lead flash or protrusions. 5. Controlling dimensions in inches [mm]. 0.027 (0.70)
0.100 (2.54) 0.050 (1.27) 0.050 (1.27)
0.378 (9.60) Ref.
0.059 (1.50)
0.155 (3.93)
PIN 7 0.059 (1.50)
DETAIL A 0.100 (2.54) 0.100 (2.54)
MOUNTING HOLE PATTERN (not to scale)
PI-4917-042010
34
Rev. B 03/10
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TOP264-271
eDIP-12 (V Package)
0.004 [0.10] C A
2
Pin #1 I.D. (Laser Marked) 2X 0.004 [0.10] C B
2
0.316 [8.03] Ref. 1 234 5 6
Seating Plane 0.010 [0.25] Ref.
C
0.016 [0.41] 12x 0.011 [0.28] 6
7
0.400 [10.16]
A
1
0.059 [1.50] Ref, typ.
0.350 [8.89]
0.213 [5.41] Ref.
0.412 [10.46] Ref. 0.306 [7.77] Ref.
0.400 [10.16]
0.436 [11.08] 0.406 [10.32] 7
8
0.059 [1.50] Ref, typ. 12 34 0.023 [0.58] 12x 0.018 [0.46] 0.010 (0.25) M C A B BOTTOM VIEW
B
12 11 10 9 8 TOP VIEW
7 Detail A 0.104 [2.65] Ref. END VIEW 5 4
0.019 [0.48] Ref.
0.356 [9.04] Ref.
0.092 [2.34] 0.086 [2.18] 0.049 [1.23] 0.046 [1.16] 0.022 [0.56] Ref.
H
0.192 [4.87] Ref. 0.070 [1.78] 0.020 [0.51] Ref. 0.028 [0.71] Ref. DETAIL A (Not drawn to scale)
0.031 [0.80] 0.028 [0.72]
SIDE VIEW
Notes: 1. Dimensioning and tolerancing per ASME Y14.5M-1994. 2. Dimensions noted are determined at the outermost extremes of the plastic body exclusive of mold flash, tie bar burrs, gate burrs, and interlead flash, but including any mismatch between the top and bottom of the plastic body. 3. Dimensions noted are inclusive of plating thickness. 4. Does not include inter-lead flash or protrusions. 5. Controlling dimensions in inches (mm). 6. Datums A & B to be determined at Datum H. 7. Measured with the leads constrained to be perpendicular to Datum C. 8. Measured with the leads unconstrained. 9. Lead numbering per JEDEC SPP-012.
PI-5556-122109
Part Ordering Information
* TOPSwitch Product Family * JX Series Number * Package Identifier E V G TOP 264 E G - TL Blank Plastic eSIP-7C Plastic eDIP-12 Halogen Free and RoHS Compliant Standard Configurations
* Pin Finish * Tape & Reel and Other Options
35
www.powerint.com
Rev. B 03/10
Revision A B B
Notes Release data sheet. Added eDIP parts. Page 4 "latching" changed to "hysteretic". Table 4 updated.
Date 01/10 01/10 03/10
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. Life Support Policy POWER INTEGRATIONS PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF POWER INTEGRATIONS. As used herein: 1. A Life support device or system is one which, (i) is intended for surgical implant into the body, or (ii) supports or sustains life, and (iii) whose failure to perform, when properly used in accordance with instructions for use, can be reasonably expected to result in significant injury or death to the user. 2. A critical component is any component of a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system, or to affect its safety or effectiveness. The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StakFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)2010, Power Integrations, Inc.
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