®
Design Idea DI-16
TOP S w it c h®-GX 57 W, 230 VAC,
Multi-output Set-top Box Power Supply
Topology
Flyback
Device
Power Output
Input Voltage
Output Voltage
Application
Set-top Box
43 W cont./57 W peak 180-265 VAC
TOP246Y
3.3 V / 5 V / 12 V / 18 V / 33 V
Design Highlights
• High efficiency, >75% at 180 VAC
• Good cross-regulation with no linear regulators
• Line undervoltage detection (UV) and overvoltage (OV)
power system surge protection
• Meets CISPR22B/EN55022B conducted EMI limits
• Differential and common mode surge immunity to 4 kV
(EN61000-4-5)
down, the drain voltage does not exceed the DC input
voltage (drain does not switch), allowing the AC rail to
rise to 495 VAC (700 VDC BVDSS rating) without
damaging the TOPSwitch-GX.
• Transformer T1 is constructed using a slotted bobbin,
enabling automated transformer winding and assembly.
• The transformer turns ratio is optimized (including output
diode forward drops) to minimize the output voltage error
between the 3.3 V and 5 V outputs.
• 100 kHz ring wave immunity to 4 kV (IEEE C62.41)
• Feedback is taken from both the 3.3 V and 5 V outputs to
the reference (U3) via R10, R11 and R13. Other output
voltages are set by the transformer turns ratio. The 12 V,
18 V, and 33 V outputs are DC-stacked on the 5 V output
for enhanced regulation and voltage centering. Pre-load
resistor R14 is required to maintain regulation of the 33 V
output when lightly loaded.
Key Design Points
• R1 (2 MΩ, 0.5 W) sets UV at 100 VDC and OV at
450 VDC. A 0.5 W resistor is required to give a voltage
rating greater than 350 VDC.
• Integrated OV shut-down protects against long duration line
voltage surges (common in some countries). During shut-
T1
R6
10 Ω
D7
UF4003
PERFORMANCE SUMMARY
Output Power:
L6
33 µH, 0.2 A
33 V, 0.03 A
18 V, 0.5 A
45 W Cont./
57 W Peak
18
17
16
C7
C8
10 µF
50 V
47 µF
50 V
L2
D8
UF5402
Regulation:
3.3 V:
5 V:
12 V:
18 V:
33 V:
3.3 µH, 5 A
± 5%
± 5%
± 7%
± 7%
± 8%
≥75%
0.6 W
C9
C10
1000 µF
L3
12 V,
0.6 A/1.8 A pk
D9
UF5402
100 µF
25 V
3.3 µH, 5 A
25 V
L7
Bead
C11
Efficiency:
No-Load Consumption:
390 µF
10
C12
100 µF
25 V
R14
2.7 kΩ
0.5 W
35 V
C24
0.1 µF
R15
10
Ω
50 V
L4
3.3 µH
5A
C5
1 nF
1 kV
R2
68 kΩ
2 W
5 V, 3.2 A
C6
2.2 nF
Y1
11
C13, C14
1000 µF
35 V
L5
C15
220 µF
16 V
D10
BYV32-200
3.3 µH
1
5A
3.3 V, 3 A
RTN
D1-D4
1N4007V
1 A, 1000 V
14, 15
VR1
C18
P6KE200
D11
C16, 17
220 µF
MBR1045
1000 µF
16 V
35 V
12, 13
3, 4
D2
D4
D1
D3
D5
UF4005
R7
150 Ω
5
C2
68 µF
8
9
C3
1 µF
50 V
L1
20 mH
0.8 A
400 V
D6
1N4148
U2
LTV817
R1
2 MΩ
1/2 W
C1
R10
9.53 kΩ
1%
R8
1 kΩ
R13
15 kΩ
1%
0.1 µF
X2
C19
0.1 µF
50 V
TOP S w it c h -GX
D
S
L
RV1
275 V
14 mm
CONTROL
U1
C
R9
3.3 kΩ
TOP246Y
F1
R3
6.8 Ω
3.15 A
C3
C20
22 µF
50 V
X
F
R4
9.09 k
1%
0.1 µF
50 V
RT1
10 Ω
1.7 A
U3
TL431CLP
t°
C5
47 µF
16 V
L
R11
180 - 265
10 kΩ
VAC
1%
N
PI-3395-100102
Figure 1. TOPSwitch-GX 60 W Set-top Box Output Power Supply.
December 2002
DI-16
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