DI-143 Design Idea

TOPSwitch-HX ®

High Efficiency Inkjet Power Supply Provides up to 80 Watts of Peak Power

Application Device Power Output Input Voltage Output Voltage Topology

Inkjet Printer TOP258MN 20 W cont, 80 W pk 90 – 264 VAC 32 V Flyback

Design Highlights typically have peak load requirements applied for very short
• Low component count, high efficiency periods.
• Meets CEC/ENERGY STAR 2008 requirements
• Delivers 20 W continuous and 80 W of peak power The TOP258MN regulates the output by adjusting the duty cycle
• Very high efficiency in standby and sleep modes of the internal MOSFET in proportion to the current fed into the
• Enables more than 0.6 W output power for 1 W input power at CONTROL pin. The feedback signal is provided from the second-
240 VAC input ary via a simple low cost Zener diode (VR3) and optocoupler (U2)
• Enables more than 2.3 W output power for <3 W input power
at 240 VAC input The EcoSmart® multimode control feature of TOPSwitch-HX
• Very low no-load input power <300 mW at 240 VAC provides a virtually constant efficiency over the entire load range.
• Time-triggered overvoltage protection (OVP)
• Latching fault protection and fast AC reset To provide a constant output power with line voltage, R11, R14
• Meets EN55022 and CISPR-22 Class B conducted EMI with and R12 linearly reduce the internal current limit of U4 as the line
>10 dBμV margin voltage increases. This allows the supply to limit the output power
• Limited Power Source (LPS) with maximum apparent power not to <100 VA at high line while still delivering the rated output power
exceeding 100 VA in fault conditions at low line.
Operation The power supply has time-triggered overload protection sensed
The isolated flyback converter shown in Figure 1 is designed from the primary side bias winding. During overload, the voltage
around the TOPSwitch-HX IC family, the part used is TOP258MN across C13 rises. Once this exceeds 20 V (VR5), the latching
(U4). The power supply operates from a universal input voltage shutdown feature of the VOLTAGE MONITOR (V) pin is triggered.
range and is designed to provide a 32 V output delivering 20 W The values of C9, R20 and R22 determine the delay before
continuous with 80 W peak. The M package (10-pin DIP) allows triggering the OV latch. Once in latching shutdown, the V pin
simultaneous use of current limit programming, line sense and
C8
OVP functions. Ideal applications include inkjet printers, which 1 nF R19 C26
68 7 100 pF
250 VAC
0.5 W 1 kV
C20 C31 32 V
330 MF 22 MF 625 mA, 2.5 APK
50 V L2 50 V L3
1 10
3.3 MH

2 D6-D7
D8 D9 VR7 STPS3150 RTN
R25 9
1N4007 1N4007 BZY97C150 47 MH
C3 100 7
120 MF 150 V C29
o 400 V 5
t 3 C13 220 nF
R1 R11 NC 10 MF C10 50 V
RT1 2 M7 3.6 M7 R17 C5 50 V
D11 D10 1 nF
1N4007 1N4007 10 7 1 k7 10 nF 4 250 VAC
0.5 W 1 kV
T1 D5
EF25 LL4148 R10
56 7 R8
L1 1.5 k7
5.3 mH D2
R2 R14 1N4007GP C28
D13 2 M7 3.6 M7 330 nF
1N4007 50 V
R23 R24 VR3
1N5255B
1 M7 1 M7 28 V
U2A
VR5 R20 PC817D
R3 1N5250B C9
R22 1 MF 130 k7
2 M7 20 V
C1 D V 2 M7 100 V
F1 R21
220 nF 3.15 A CONTROL R9
275 VAC 1 M7 2 k7
R4 0.125 W
2 M7
C
90 - 264 PI-4793-102307
VAC S X
R15
1 k7 R6
R12 TOPSwitch-HX 6.8 7
Q1 C6
7.5 k7 U4 100 nF
C30 2N3904 1% TOP258MN 50 V
100 nF
400 V Q2
Q3 C7
2N3904
2N3904 47 MF
R26 16 V
68 k7 R18
39 k7

Figure 1. Universal input, 20 W Continuous, 80 W Peak Power Inkjet Printer Power Supply Using TOP258MN.

www.powerint.com October 2007

needs to discharge below a fixed threshold before switching can 80

PI-4794-102307
be reinitiated. This is accomplished by a fast AC reset circuit. On
70
loss of AC, Q3 turns off, turning on Q1 and pulling the V pin low to
QP
reset the OVP latch. 60
AV
Key Design Points 50
• For printers the voltage regulation requirement (±7%) allows a
40
simple low cost Zener VR3 to be used to set the output voltage.

dBMV
For tighter voltage tolerances, a shunt regulator like a TL431 30
may be used. 20
• The primary clamp circuit (D2, VR7, R17, C5 and R25) provides
very high light-load efficiency. Zener VR7 and R17 discharge 10
capacitor C5 every cycle and limit to an average clamping 0
voltage. During lower switching frequency operation, the
capacitor cannot discharge below the rated voltage of VR7, -10
which improves light load efficiency. -20
• Selecting D2 as a slow diode (≤2 μs recovery) allows for some 0.15 1.0 10.0 100.0
of the leakage energy to be recycled into the load. If glass MHz
passivated 1N4007 is not available, the plastic FR106 may be Figure 2. Worst Case Conducted EMI (230 VAC with Output Grounded).
substituted.
• Within the normal operating range, Q3 turns on, thereby turning
off Q1. Resistors R1 and R2 can thus inject current into the Transformer Parameters
V pin of U4 and provide line undervoltage detection. Once the EF25 NC-2H or equivalent,
Core Material
current into the V pin exceeds 25 μA, switching is enabled. gapped for ALG of 70 nH/t²
• At very low input voltages, transistor Q2 turns off, thus leaving Bobbin BEF25, 10 pin, Horizontal
the X pin floating. This in turn inhibits switching of U4, and the
3mm margins on primary side of bobbin to meet
power supply turns off.
safety
• Capacitors C1, C3, C8, C10 and common-mode chokes L1 Primary: 48T x 2, AWG31, tape
and L3 provide common mode filtering. Winding Details Bias: 9T x 4, AWG29, 3 layers, tape
• Phase boost network R10 and C28 provides high frequency 32 V: 24T x 2, AWG28, TIW, 3 layers tape
gain and increased phase margin. Shield: 10T x 4, AWG30, tape
Primary: 48T x 2, AWG31, tape
Primary(3 – 2), Bias(5 – 4), 32 V(10 – 9)
Winding Order
Shield(NC – 1), Primary(2 – 1)
Primary Inductance 648 μH, ±20%
Primary Resonant 1000 kHz (minimum)
Frequency
Leakage 16 μH (maximum)
Inductance

Table 1. Transformer Parameters. (NC = No Connection, TIW = Triple Insulated Wire).

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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.
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©2007, Power Integrations, Inc.

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10/07 DI-143