TOP242-249

Manufacturer Part NumberTOP242-249
DescriptionFamily Extended Power, Design Flexible,Integrated Off-line Switcher
ManufacturerPOWERINT [Power Integrations, Inc.]
TOP242-249 datasheet
 


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TOP242-249
TOPSwitch -GX Family
Extended Power, Design Flexible,
®
EcoSmart
, Integrated Off-line Switcher
Product Highlights
Lower System Cost, High Design Flexibility
• Extended power range to 250 W
• Features eliminate or reduce cost of external components
• Fully integrated soft-start for minimum stress/overshoot
• Externally programmable accurate current limit
• Wider duty cycle for more power, smaller input capacitor
• Separate line sense and current limit pins on Y/R packages
• Line under-voltage (UV) detection: no turn off glitches
• Line overvoltage (OV) shutdown extends line surge limit
• Line feed forward with maximum duty cycle (DC
reduction rejects line ripple and limits DC
• Frequency jittering reduces EMI and EMI filtering costs
• Regulates to zero load without dummy loading
• 132 kHz frequency reduces transformer/power supply size
• Half frequency option in Y/R packages for video applications
• Hysteretic thermal shutdown for automatic fault recovery
• Large thermal hysteresis prevents PC board overheating
EcoSmart - Energy Efficient
• Extremely low consumption in remote off mode
(80 mW @ 110 VAC, 160 mW @ 230 VAC)
• Frequency lowered with load for high standby efficiency
• Allows shutdown/wake-up via LAN/input port
Description
TOPSwitch-GX uses the same proven topology as TOPSwitch,
cost effectively integrating the high voltage power MOSFET,
PWM control, fault protection and other control circuitry onto
a single CMOS chip. Many new functions are integrated to
reduce system cost and improve design flexibility, performance
and energy efficiency.
Depending on package type, the TOPSwitch-GX family has
either 1 or 3 additional pins over the standard DRAIN, SOURCE
and CONTROL terminals. allowing the following functions:
line sensing (OV/UV, line feedforward/DC max reduction),
accurate externally set current limit, remote on/off, and
synchronization to an external lower frequency and frequency
selection (132 kHz/66 kHz).
All package types provide the following transparent features:
Soft-start, 132 kHz switching frequency (automatically reduced
at light load), frequency jittering for lower EMI, wider DC
hysteretic thermal shutdown and larger creepage packages. In
addition, all critical parameters (i.e. current limit, frequency,
PWM gain) have tighter temperature and absolute tolerance, to
simplify design and optimize system cost.
®
AC
IN
)
MAX
at high line
MAX
Figure 1. Typical Flyback Application.
PRODUCT
TOP242 P or G
TOP242 R
TOP242 Y
TOP243 P or G
TOP243 R
TOP243 Y
TOP244 P or G
TOP244 R
TOP244 Y
TOP245 R
TOP245 Y
TOP246 R
TOP246 Y
TOP247 R
TOP247 Y
TOP248 R
TOP248 Y
TOP249 R
TOP249 Y
Table 1. Notes: 1. Typical continuous power in a non-ventilated
enclosed adapter measured at 50 °C ambient. Assumes 1 sq. in. of
2 oz. copper heat sink area for R package. 2. Maximum practical
,
MAX
continuous power in an open frame design at 50 °C ambient. See
Key Applications for detailed conditions. Assumes 3 sq. in. of 2 oz.
copper heat sink area for R package. 3. See Part Ordering Information.
4. 230 VAC or 100/115 VAC with doubler.
D
L
CONTROL
C
TOPSwitch-GX
S
X
F
OUTPUT POWER TABLE
±
230 VAC
15%
4
3
Open
1
Adapter
Adapter
2
Frame
9 W
15 W
10 W
22 W
10 W
22 W
13 W
25 W
20 W
43 W
13 W
45 W
16 W
30 W
28 W
52 W
30 W
65 W
33 W
58 W
40 W
85 W
37 W
65 W
60 W
125 W
41 W
73 W
85 W
165 W
43 W
78 W
105 W
205 W
45 W
82 W
120 W
250 W
®
+
DC
OUT
-
PI-2632-060200
85-265 VAC
Open
1
Frame
2
6.5 W
10 W
7 W
14 W
7 W
14 W
9 W
15 W
15 W
23 W
15 W
30 W
11 W
20 W
18 W
28 W
20 W
45 W
20 W
32 W
26 W
60 W
24 W
36 W
40 W
90 W
26 W
43 W
55 W
125 W
28 W
48 W
70 W
155 W
30 W
52 W
80 W
180 W
July 2001

TOP242-249 Summary of contents

  • Page 1

    ... TOP242-249 TOPSwitch -GX Family Extended Power, Design Flexible, ® EcoSmart , Integrated Off-line Switcher Product Highlights Lower System Cost, High Design Flexibility • Extended power range to 250 W • Features eliminate or reduce cost of external components • Fully integrated soft-start for minimum stress/overshoot • Externally programmable accurate current limit • ...

  • Page 2

    ... TOP242-249 Functional Block Diagram ......................................................................................................................................... 3 Pin Functional Description ........................................................................................................................................ 4 TOPSwitch-GX Family Functional Description ........................................................................................................ 5 CONTROL (C) Pin Operation ................................................................................................................................. 6 Oscillator and Switching Frequency ....................................................................................................................... 6 Pulse Width Modulator and Maximum Duty Cycle ................................................................................................. 7 Light Load Frequency Reduction ............................................................................................................................ 7 Error Amplifier ......................................................................................................................................................... 7 On-chip Current Limit with External Programmability ............................................................................................. 7 Line Under-Voltage Detection (UV) ........................................................................................................................ 8 Line Overvoltage Shutdown (OV) ........................................................................................................................... 8 ...

  • Page 3

    ... SHUTDOWN/ AUTO-RESTART STOP LOGIC HYSTERETIC THERMAL SHUTDOWN STOP SOFT- START D MAX DC MAX CLOCK SAW - + OSCILLATOR WITH JITTER PWM COMPARATOR LIGHT LOAD FREQUENCY REDUCTION TOP242-249 DRAIN (D) INTERNAL SUPPLY - + CURRENT LIMIT COMPARATOR CONTROLLED TURN-ON GATE DRIVER S Q LEADING EDGE R BLANKING SOURCE (S) PI-2639-060600 PI-2639-060600 ...

  • Page 4

    ... TOP242-249 Pin Functional Description DRAIN (D) Pin: High voltage power MOSFET drain output. The internal start- up bias current is drawn from this pin through a switched high- voltage current source. Internal current limit sense point for drain current. CONTROL (C) Pin: Error amplifier and feedback current input pin for duty cycle control ...

  • Page 5

    ... The FREQUENCY (F) pin in the package sets the reduction. In this switching frequency to the default value of 132 kHz when MAX connected to SOURCE pin. A half frequency option of 66 kHz can be chosen by connecting this pin to CONTROL pin instead. Leaving this pin open is not recommended. TOP242-249 I I CD1 B = 125 µ 190 µ ...

  • Page 6

    ... TOP242-249 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 V is the supply voltage for the control circuitry C including the MOSFET gate driver ...

  • Page 7

    ... By setting current limit low, a larger TOPSwitch-GX than necessary for the power required can be used to take advantage of the lower R higher efficiency/smaller heat sinking requirements. With a August 8, 2000 TOP242-249 4 ms Time waveform) DRAIN C of the output MOSFET ...

  • Page 8

    ... TOP242-249 second resistor connected between the EXTERNAL CURRENT LIMIT (X) pin ( package) or MULTI-FUNCTION (M) pin ( package) 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 ...

  • Page 9

    ... PC board due to a continuous fault condition regulated in hysteretic mode C and a 4 5.8 V (typical) sawtooth waveform is present on the CONTROL pin while in thermal shutdown. Bandgap Reference All critical TOPSwitch-GX internal voltages are derived from a temperature-compensated bandgap reference. This reference is August 8, 2000 TOP242-249 7/01 ...

  • Page 10

    ... TOP242-249 also used to generate a temperature-compensated current reference which is trimmed to accurately set the switching frequency, MOSFET gate drive current, current limit, and the line OV/UV thresholds. TOPSwitch-GX has improved circuitry to maintain all of the above critical parameters within very tight absolute and temperature tolerances. ...

  • Page 11

    ... See Figure ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ TOP242-249 (+50 µA typical with UV (+225 µA typical with OV reduction lowers maximum duty cycle MAX (+60 µA typical L(DC ✔ ...

  • Page 12

    ... TOP242-249 Figure Number Three Terminal Operation Under-Voltage Overvoltage Line Feed Forward (DC ) MAX Overload Power Limiting External Current Limit Remote ON/OFF *This table is only a partial list of many MULTI-FUNCTION pin configurations that are possible. Table 3. Typical MULTI-FUNCTION Pin Configurations. 11 for a description of the functions where the horizontal axis (left hand side) represents the EXTERNAL CURRENT LIMIT pin current ...

  • Page 13

    ... Figure 11. MULTI-FUNCTION ( package), LINE-SENSE, and EXTERNAL CURRENT LIMIT ( package) Pin Characteristics. M Pin I I REM(N) UV Disabled when supply output goes out of regulation -22 µA -27 µ -100 - 100 TOP242-249 L Pin 150 200 250 300 350 August 8, 2000 400 PI-2636-040501 E 13 ...

  • Page 14

    ... TOP242-249 CONTROL Pin EXTERNAL CURRENT LIMIT (X) LINE-SENSE (L) Figure 12a. LINE-SENSE (L), and EXTERNAL CURRENT LIMIT (X) Pin Input Simplified Schematic. CONTROL Pin MULTI-FUNCTION (M) Figure 12b. MULTI-FUNCTION (M) Pin Input Simplified Schematic August 8, 2000 7/01 Y and R Package TOPSwitch-GX 240 µA (Negative Current Sense - ON/OFF, Current Limit Adjustment) ...

  • Page 15

    ... Figure 15. Half Frequency Standby Mode (For High Standby Input Voltage C PI-2654-071700 Figure 14. Half Frequency Operation (66 kHz can be an optocoupler output Input CONTROL Voltage kΩ - Efficiency). TOP242-249 + DC D CONTROL STANDBY 47 kΩ S PI-2656-040501 August 8, 2000 PI-2655-071700 E 15 7/01 ...

  • Page 16

    ... TOP242-249 Typical Uses of LINE-SENSE (L) and EXTERNAL CURRENT LIMIT (X) Pins + DC Input Voltage D L CONTROL Figure 16. Three Terminal Operation (LINE-SENSE and EXTERNAL CURRENT LIMIT Features Disabled. FREQUENCY Pin can be tied to SOURCE or CONTROL Pin MΩ kΩ Input Voltage D M CONTROL C 6 Figure 18 ...

  • Page 17

    ... For MΩ 100 VDC UV Input V = 450 VDC OV Voltage C PI-2622-040501 Figure 27. Active-on Remote ON/OFF with LINE-SENSE and TOP242-249 Q can optocoupler output or can be replaced by a manual switch ON/OFF R 47 kΩ kΩ ...

  • Page 18

    ... TOP242-249 Typical Uses of LINE-SENSE (L) and EXTERNAL CURRENT LIMIT (X) Pins (cont MΩ Input CONTROL Voltage kΩ - Figure 28. Line-Sensing and Externally Set Current Limit August 8, 2000 7/ For MΩ ...

  • Page 19

    ... LIMIT For kΩ 43% LIMIT See fig. 55 for other Input resistor values ( Voltage to select different I values LIMIT C PI-2517-040501 Figure 35. Current Limit Reduction with Line Voltage. TOP242-249 + For MΩ 100 VDC 450 VDC OV ...

  • Page 20

    ... TOP242-249 Typical Uses of MULTI-FUNCTION (M) Pin (cont output or can be replaced by a manual switch. DC Input Voltage D M CONTROL Q R ON/OFF 47 kΩ Figure 36. Active-on (Fail Safe) Remote ON/OFF output or can be replaced by a manual switch. DC Input Voltage CONTROL ON/OFF 47 kΩ ...

  • Page 21

    ... MΩ 1 4.7 MΩ 1/2 W TOPSwitch- CONTROL CONTROL C TOP244Y R5 6.8 Ω 9.09 kΩ 47 µ TOP242-249 L3 3.3 µH C10 C11 220 µF 560 µF 560 µ 150 Ω R8 150 Ω C6 0.1 µF U2 LTV817A VR2 1N5240C August 8, 2000 ...

  • Page 22

    ... TOP242-249 A High Efficiency, Enclosed Universal Adapter Supply The circuit shown in figure 42 takes advantage of several of the TOPSwitch-GX features to reduce cost, power supply size and increase efficiency. This design delivers from 265 VAC input ambient of 40 ° small sealed adapter case (4” ...

  • Page 23

    ... V D1 BYV26C D2 1N4148 T1 TOPSwitch-GX TOP249Y CONTROL CONTROL 6.8 Ω C3 0.1 µ µ TOP242-249 C10 C11 L2 560 µF 560 µF 3 µ 5 C12 68 µ LTV817A kΩ 1 µ 100 Ω C13 D4 150 nF ...

  • Page 24

    ... TOP242-249 Multiple Output 185-265 VAC Input Power Supply Figure 44 shows a multiple output supply typical for high end set-top boxes or cable decoders containing high capacity hard disks for recording. The supply delivers an output power cont./60 W peak (thermally limited) from an input voltage of 185 to 265 VAC. Efficiency 185 VAC is ≥ ...

  • Page 25

    ... Peripherals are usually designed to turn off automatically if they are not being used for a period of time, to save power. 27 kΩ U2 TOPSwitch- µ TOP242-249 may be needed to prevent noise coupling to the pin M External Wake-up Signal Power MICRO Supply PROCESSOR/ 100 kΩ ...

  • Page 26

    ... TOP242-249 In addition to using a minimum number of components, TOPSwitch-GX provides many technical advantages in this type of application: 1. Extremely low power consumption in the off mode typical at 110 VAC and 160 mW typical at 230 VAC. This is because in the remote/off mode the TOPSwitch-GX consumes very little power, and the external circuitry does not consume any current (either pin is open) from the high voltage DC input ...

  • Page 27

    ... Lower EMI (second harmonic below 150 kHz) ±4 kHz@132 kHz 9,46 • Reduces conducted EMI ±2 kHz@66 kHz At a Duty Cycle 7 • Zero load regulation without dummy below 10% load • Low power consumption at no load TOP242-249 ) OR August 8, 2000 E 27 7/01 ...

  • Page 28

    ... TOP242-249 TOPSwitch-II Function Remote ON/OFF N/A* Synchronization N/A* 125 °C min. Thermal Shutdown Latched Current Limit Tolerance ±10% (@25 °C) -8% (0 °C to100 °C) -4% (0 °C to 100 °C) DRAIN DIP 0.037" / 0.94 mm Creepage SMD 0.037" Package TO-220 0.046" / 1.17 mm DRAIN Creepage at 0.045" / 1.14 mm PCB for Y and R ...

  • Page 29

    ... V is recommended to allow OR 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 TOPSwitch-GX MOSFET. TOP242-249 reduction optimized for MAX than MAX OR ...

  • Page 30

    ... TOP242-249 A high V is required to take full advantage of the wider TOPSwitch-GX. An RCD clamp provides tighter clamp voltage tolerance than a Zener clamp and allows 150 V. RCD clamp dissipation can be minimized by reducing the external current limit as a function of input line voltage (see Figure 21 and 35). The RCD clamp is more cost effective than the Zener clamp but requires more careful design (see quick design checklist) ...

  • Page 31

    ... Thermal check – At maximum output power, minimum input voltage and maximum ambient temperature, verify that temperature specifications are not exceeded for TOPSwitch-GX, transformer, output diodes and output capacitors. Enough thermal margin should be allowed for August 8, 2000 TOP242-249 does not 7/01 ...

  • Page 32

    ... TOP242-249 + HV Input Filter Capacitor - S TOP VIEW R1 R2 Figure 47. Layout Considerations for TOPSwitch-GX using Packages. + Input Filter Capacitor HV - TOPSwitch-GX TOP VIEW R1 Heat Sink Figure 48. Layout Considerations for TOPSwitch-GX using Y Package August 8, 2000 7/01 Safety Spacing Y1- Capacitor PRI BIAS PRI S D TOPSwitch-GX ...

  • Page 33

    ... PRI Input Filter Capacitor PRI BIAS Opto- coupler Design Tools of TOPSwitch- date information on design tools can be found at the Power Integrations Web site: www.powerint.com TOP242-249 Output Filter Capacitors Y1 SEC Maximize hatched copper areas( ...

  • Page 34

    ... TOP242-249 DRAIN Voltage ............................................ -0.3 to 700 V DRAIN Peak Current: TOP242 ............................... 0.72 A TOP243 ............................... 1.44 A TOP244 ............................... 2.16 A TOP245 ............................... 2.88 A TOP246 ............................... 4.32 A TOP247 ............................... 5.76 A TOP248 ............................... 7.20 A TOP249 ............................... 8.64 A CONTROL Voltage .......................................... -0 CONTROL Current ............................................... 100 mA Thermal Impedance: Y Package (θ (θ Package: ) ...... 45 °C/W (θ JA ......................... 11 °C/W (5) (θ Parameter Symbol CONTROL FUNCTIONS Switching Frequency f OSC ...

  • Page 35

    ... mA See Note A TOP242-245 See Figure 7 TOP246-249 TOP242-245 = 25 ° TOP246-249 = 25 ° mA See Figure ° See Note A TOP242-249 Min Typ Max Units -28 -23 -18 %/mA -0.01 %/mA/°C 1.2 2.0 3.0 mA 1.6 2.6 4.0 6.0 7.0 mA 6.6 8.0 Ω 0.18 %/°C 7 kHz -5 ...

  • Page 36

    ... TOP242-249 Parameter Symbol MULTI-FUNCTION (M), LINE-SENSE (L) AND EXTERNAL CURRENT LIMIT (X) INPUTS Line Under-Voltage Threshold Current l UV and Hysteresis ( Pin) Line Over-Voltage or Remote ON/ I OFF Threshold OV Current and Hys- teresis ( Pin) L Pin Voltage V L(TH) Threshold Remote ON/OFF Negative Threshold I REM (N) Current and Hyster- ...

  • Page 37

    ... See Note C J Internal;di/dt=1080 mA/µs TOP249 Y °C T See Note C J ≤ 85 VAC (Rectified Line Input) See Note B 265 VAC (Rectified Line Input) See Fig ° TOP242-249 Min Typ Max Units µs 2.5 µs 2.5 2.9 V µ 100 0.418 0.45 0.481 0.697 0.75 0.802 ...

  • Page 38

    ... TOP242-249 Parameter Symbol CIRCUIT PROTECTION (cont) t Current Limit Delay IL(D) Thermal Shutdown Temperature Thermal Shutdown Hysteresis Power-up Reset V Threshold Voltage C(RESET) OUTPUT ON-State R Resistance DS(ON) Off-State I DSS Current Breakdown BV Voltage DSS Rise t R Time Fall t Time August 8, 2000 7/01 Conditions (Unless Otherwise Specified) See Figure 53 = -40 to 125 ° ...

  • Page 39

    ... See Figure 53 = -40 to 125 °C ; SOURCE = See Note Output TOP 242-245 MOSFET Enabled TOP 246-249 L M Output MOSFET Disabled TOP242-249 Min Typ Max Units 36 V 5.60 5.85 6.10 V ±50 ppm/°C 1.0 1.6 2.5 1.2 2.2 3.2 mA 0.3 0.6 1.3 ) vs. DRAIN voltage C August 8, 2000 ...

  • Page 40

    ... TOP242-249 VOLTAGE Figure 50. Duty Cycle Measurement. 120 100 Dynamic 1 = Impedance Slope CONTROL Pin Voltage (V) Figure 51. CONTROL Pin I-V Characteristic Package (X and L Pin) S1 470 Ω 470 Ω µF NOTES: 1. This test circuit is not applicable for current limit or output characteristic measurements. ...

  • Page 41

    ... Temporarily shorting the CONTROL pin to the SOURCE pin will reset TOPSwitch-GX, which then will come up in the correct state. -150 -100 I (µA) M Maximum 15K 20K 25K 30K External Current Limit Resistor R (Ω) IL TOP242-249 power supply be turned on first C PI-2653-033001 Scaling Factors: 200 TOP242: .45 180 TOP243 P/G: .75 TOP243 Y/R: .90 160 TOP244 P/G: 1 TOP244 Y/R: 1 ...

  • Page 42

    ... TOP242-249 Typical Performance Characteristics (cont.) 1.1 1.0 0.9 -50 - 100 125 150 Junction Temperature (°C) Figure 56. Breakdown Voltage vs. Temperature. 1.2 1.0 0.8 0.6 0.4 0.2 0 -50 - 100 125 150 Junction Temperature (°C) Figure 58. Internal Current Limit vs. Temperature. 1.2 1.0 0.8 0.6 0.4 0.2 0 -50 - 100 125 150 Junction Temperature (°C) Figure 60 ...

  • Page 43

    ... Figure 64. Control Current Out at 0% Duty Cycle vs. Temperature. 300 400 EXTERNAL CURRENT LIMIT Pin Current (µA) Figure 62b. EXTERNAL CURRENT LIMIT Pin Voltage Figure 63b. MULTI-FUNCTION Pin Voltage vs. Figure 65. Max. Duty Cycle Reduction Onset Threshold TOP242-249 1.6 = 1.33 - I x 0.66 kΩ 1.4 ≤ ...

  • Page 44

    ... TOP242-249 Typical Performance Characteristics (cont Scaling Factors: TOP249 1.00 TOP248 0.83 2 TOP247 0.67 TOP246 0.50 TOP245 0.33 1 TOP244 0.25 TOP243 0.17 TOP242 0. DRAIN Voltage (V) Figure 66. Output Characteristics. 10000 Scaling Factors: 1000 TOP249 1.00 TOP248 0.83 TOP247 0.67 TOP246 0.50 TOP245 0.33 TOP244 0.25 TOP243 0.17 100 TOP242 0 ...

  • Page 45

    ... Minimum metal to metal spacing at the pack- PIN 7 age body for omitted pin locations is .068 inch (1.73 mm). .150 (3.81) 5. Position of terminals to be measured at a location .25 (6.35) below the package body. 6. All terminals are solder plated. TOP242-249 (242, 243 & 244 only) .045 (1.14) .055 (1.40) .570 (14.48) REF. .670 (17.02) REF. ...

  • Page 46

    ... TOP242-249 ⊕ .004 (.10) -E- .245 (6.22) .255 (6.48) Pin 1 .375 (9.53) -D- .385 (9.78) .128 (3.25) .132 (3.35) -T- SEATING PLANE .100 (2.54) BSC .048 (1.22) .053 (1.35) .014 (.36) ⊕ .010 (.25) M .022 (.56) ⊕ .004 (.10) -E- .245 (6.22) .255 (6.48) Pin 1 .100 (2.54) (BSC) .375 (9.53) -D- .385 (9.78) .128 (3.25) .132 (3.35) .032 (.81) .048 (1.22) .053 (1.35) ...

  • Page 47

    ... Notes: 1. Package Outline Exclusive of Mold Flash & Metal Burr. 2. Package Outline Inclusive of Plating Thickness. .128 (3.25) 3. Foot Length Measured at Intercept Point Between Datum A Lead Surface. 4. Controlling Dimensions are in Inches. Millimeter Dimensions are shown in Parentheses. TOP242-249 .045 (1.14) .055 (1.40) .000 (0.00) .010 (0.25) .090 (2.29) .110 (2.79) -A- .010 (0.25) ...

  • Page 48

    ... TOP242-249 Revision Notes - D 1) Added R package (D2PAK Corrected abbreviations (s = seconds). 3) Corrected x-axis units in Figure 11 (µA). 4) Added missing external current limit resistor in Figure Corrected spelling. 6) Added caption for Table 4. 7) Corrected Breakdown Voltage parameter condition (T 8) Corrected font sizes in figures. ...