A High Efficiency, 150 W, 250-380 Vdc Input Power Supply - Power integrations TOPSwitch-HX Series Manual

TOP252-262
A High Efficiency, 150 W, 250 – 380 VDC Input
Power Supply
The circuit shown in Figure 42 delivers 150 W (19 V @ 7.7 A) at
84% efficiency using a TOP258Y from a 250 VDC to 380 VDC
input. A DC input is shown, as typically at this power level a
power factor correction stage would precede this supply,
providing the DC input. Capacitor C1 provides local decoupling,
necessary when the supply is remote from the main PFC output
capacitor.
The flyback topology is still usable at this power level due to the
high output voltage, keeping the secondary peak currents low
enough so that the output diode and capacitors are reasonably
sized. In this example, the TOP258YN is at the upper limit of its
power capability.
Resistors R3, R6 and R7 provide output power limiting,
maintaining relatively constant overload power with input voltage.
Line sensing is implemented by connecting a 4 MW resistor from
the V pin to the DC rail. Resistors R4 and R5 together form the
4 MW line sense resistor. If the DC input rail rises above
450 VDC, then TOPSwitch-HX will stop switching until the
voltage returns to normal, preventing device damage.
Due to the high primary current, a low leakage inductance
transformer is essential. Therefore, a sandwich winding with a
copper foil secondary was used. Even with this technique, the
leakage inductance energy is beyond the power capability of a
simple Zener clamp. Therefore, R1, R2 and C3 are added in
parallel to VR1 and VR3, two series TVS diodes being used to
reduce dissipation. During normal operation, very little power is
250 - 380
VDC
F1 RT1
O
4 A
5 Ω t
R6
4.7 MΩ
R7
4.7 MΩ
C1
22 µF
400 V R20
1.5 kΩ
2 W
D5
1N4937
R21
1.5 kΩ
2 W
R22
1.5 kΩ
2 W
R3
C18
8.06 kΩ
120 pF
1%
1 kV
Figure 42. 150 W, 19 V Power Supply using TOP258YN.
22
Rev. J 08/16
R2
R1
68 kΩ
68 kΩ
2 W 2 W
C3
4.7 nF
R4
2.0 MΩ
1 kV
D1
R5
ΜΩ
2.0
VR1, VR3
R19
4.7 Ω
TOPSwitch-HX
U1
D V
TOP258YN
CONTROL
C
R10
S X F
Ω
6.8
C11
100 nF
50 V
C10
47 µF
10 V
dissipated by VR1 and VR3, the leakage energy instead being
dissipated by R1 and R2. However, VR1 and VR3 are essential
to limit the peak drain voltage during start-up and/or overload
conditions to below the 700 V rating of the TOPSwitch-HX
MOSFET. The schematic shows an additional turn-off snubber
circuit consisting of R20, R21, R22, D5 and C18. This reduces
turn-off losses in the TOPSwitch-HX.
The secondary is rectified and smoothed by D2, D3 and C5,
C6, C7 and C8. Two windings are used and rectified with
separate diodes D2 and D3 to limit diode dissipation. Four
capacitors are used to ensure their maximum ripple current
specification is not exceeded. Inductor L1 and capacitors C15
and C16 provide switching noise filtering.
Output voltage is controlled using a TL431 reference IC and
R15, R16 and R17 to form a potential divider to sense the
output voltage. Resistor R12 and R24 together limit the
optocoupler LED current and set overall control loop DC gain.
Control loop compensation is achieved using components C12,
C13, C20 and R13. Diode D6, resistor R23 and capacitor C19
form a soft finish network. This feeds current into the control
pin prior to output regulation, preventing output voltage
overshoot and ensuring startup under low line, full load
conditions.
Sufficient heat sinking is required to keep the TOPSwitch-HX
device below 110 C when operating under full load, low line
°
and maximum ambient temperature. Airflow may also be
required if a large heat sink area is not acceptable.
2.2 nF
C14
R14
47 pF
250 VAC Ω
22
C4
1 kV
0.5 W
13,14
1
D2
MBR20100CT
11
12
D3
MBR20100CT
4
9,10
7
D4
1N4148
5 Ω
22 47 pF
0.5 W 1 kV
T1
R12
R8
EI35
240 Ω
4.7 Ω
0.125 W
C9
10 µF
50 V
R23
15 kΩ
U2
0.125 W
PC817A
U2
PC817B
D6
1N4148
10 µF
50 V
C5-C8 C15-C16
820 µF 820 µF
L1
25 V 25 V
3.3 µH
C20
1.0 µF
50 V
R24
Ω
30
0.125 W
R16
1%
R11
C12 R17
1 kΩ
4.7 nF
Ω
562
0.125 W
50 V
1%
C13
R13
100 nF
56 kΩ
50 V
0.125 W
U3
R15
TL431
4.75 kΩ
2%
1%
PI-4795-092007
www.power.com
+19 V,
7.7 A
RTN