®
Design Idea DI-41
TOP S w it c h®-GX 43 W, 100/115 VAC
Multi-output Set-top Box Power Supply
Topology
Device
Power Output
Input Voltage
Output Voltage
Application
Flyback
Set-top Box
43 W cont. / 57 W pk 90-132 VAC
TOP247Y
3.3 V, 5 V, 12 V, 18 V, 33 V
Design Highlights
Operation
• Low cost, low component count solution
• Excellent output voltage tracking and cross-regulation - no
linear regulators required
• High efficiency, >71% at 90 VAC
• Line undervoltage detection (UV) and power system surge
protection (OV)
• Meets CISPR22B/EN55022B conducted EMI limits
• Differential and common mode surge immunity to 4 kV
(EN61000-4-5)
The design in Figure 1 utilizes the TOP247Y and takes
advantage of many of the TOPSwitch-GX features. Line UV
and OV (100 V and 450 V, respectively) are implemented
using a single 2 MΩ resistor (R1). Undervoltage eliminates
output glitches and overvoltage provides protection for both
short duration transients and long duration power system
surges. Resistor R4 programs the internal current limit of U1
to 80% of nominal, limiting overload power.
• 100 kHz ring wave immunity to 4 kV (IEEE C62.41)
Thekeyperformancecharacteristicofthecircuitshownisthe
excellent output voltage tracking and cross-regulation. Two
techniques are used to properly center the output voltages.
The extra voltage drop of the ultra-fast rectifier D10 (used
instead of a Schottky) centers the 5 V output at precisely 5 V
T1
R6
10 Ω
D7
UF4003
L6
33 µH, 0.2 A
33 V, 0.03 A
18 V, 0.5 A
14
13
12
C7
C8
L2
47 µF
50 V
D8
10 µF
50 V
3.3 µH, 5 A
UF5402
C9
C10
1000 µF
L3
12 V,
0.6 A/1.8 A pk
D9
UF5402
220 µF
25 V
3.3 µH, 5 A
25 V
L7
Bead
C11
390 µF
8
C12
100 µF
25 V
R14
35 V
5.6 kΩ
0.5 W
C24
0.1 µF
50 V
R15
10
Ω
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
9
C13, C14
1200 µF
35 V
L5
C15
220 µF
16 V
D10
3.3 µH
1
BYV32-200
5A
3.3 V, 3 A
RTN
D1-D4
RL206
11
VR1
P6KE200
2 A, 800 V
C18
C22
0.1 µF
50 V
D11
MBR1045
C16, 17
220 µF
1200 µF
16 V
35 V
3, 4
10
D2
D4
D1
D3
D5
1N4937
R7
150 Ω
5
C2
C21
0.1 µF
50 V
150 µF
7
6
C3
1 µF
50 V
L1
200 V
D6
1N4148
U2
20 mH
1.3 A
R1
LTV817
2 MΩ
1/2 W
C1
R10
R12
18 kΩ
R8
R13
15 kΩ
1%
0.22 µF
9.53 kΩ
1 kΩ
X2
1%
C19
0.1 µF
50 V
TOP S w it c h -GX
D
S
L
RV1
275 V
CONTROL
U1
TOP247Y
14 mm
C
R9
3.3 kΩ
F1
R3
6.8 Ω
3.15 A
C3
0.1 µF
50 V
C20
22 µF
50 V
X
F
R4
9.09 k
1%
RT1
10 Ω
3.2 A
U3
TL431CLP
t°
C5
L
R11
47 µF
90 - 132
VAC
10 kΩ
16 V
1%
N
PI-3389-091702
Figure 1. TOPSwitch-GX 43 W Continuous, 57 W Peak Set-Top Box Power Supply.
September 2002
DI-41
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