TOP242R POWERINT [Power Integrations, Inc.], TOP242R Datasheet - Page 31

• Manufacturer Part Number: TOP242R
• Description: TOPSwitch -GX Family Extended Power, Design Flexible, EcoSmart, Integrated Off-line Switcher
• Manufacturer: POWERINT [Power Integrations, Inc.]

switching frequency and soft-start features of TOPSwitch-GX
contribute to a smaller transformer when compared to
TOPSwitch-II.
Standby Consumption
Frequency reduction can significantly reduce power loss at light
or no load, especially when a Zener clamp is used. For very
low secondary power consumption use a TL431 regulator for
feedback control. Alternately, switching losses can be
significantly reduced by changing from 132 kHz in normal
operation to 66 kHz under light load conditions.
TOPSwitch-GX Layout Considerations
As TOPSwitch-GX has additional pins and operates at much
higher power levels compared to previous TOPSwitch
families, the following guidelines should be carefully
followed.
Primary Side Connections
Use a single point (Kelvin) connection at the negative terminal
of the input filter capacitor for TOPSwitch-GX source pin and
bias winding return. This improves surge capabilities by
returning surge currents from the bias winding directly to the
input filter capacitor.
The CONTROL pin bypass capacitor should be located as
close as possible to the SOURCE and CONTROL pins and its
SOURCE connection trace should not be shared by the main
MOSFET switching currents. All SOURCE pin referenced
components connected to the MULTI-FUNCTION, LINE-
SENSE or EXTERNAL CURRENT LIMIT pins should also
be located closely between their respective pin and SOURCE.
Once again the SOURCE connection trace of these
components should not be shared by the main MOSFET
switching currents. It is very critical that SOURCE pin
switching currents are returned to the input capacitor negative
terminal through a seperate trace that is not shared by the
components connected to CONTROL, MULTI-FUNCTION,
LINE-SENSE or EXTERNAL CURRENT LIMIT pins. This
is because the SOURCE pin is also the controller ground
reference pin.
Any traces to the M, L or X pins should be kept as short as
possible and away from the DRAIN trace to prevent noise
coupling. LINE-SENSE resistor (R1 in figures 47-49) should
be located close to the M or L pin to minimize the trace length
on the M or L pin side.
In addition to the 47 µF CONTROL pin capacitor, a high
frequency bypass capacitor in parallel may be used for better
noise immunity. The feedback optocoupler output should also
be located close to the CONTROL and SOURCE pins of
TOPSwitch-GX.
Y-Capacitor
The Y-capacitor should be connected close to the secondary
output return pin(s) and the positive primary DC input pin of
the transformer.
Heat Sinking
The tab of the Y package (TO-220) or F package (TO-262) is
internally electrically tied to the SOURCE pin. To avoid circu-
lating currents, a heat sink attached to the tab should not be
electrically tied to any primary ground/source nodes on the PC
board.
When using a P (DIP-8), G (SMD-8) or R (TO-263) package,
a copper area underneath the package connected to the
SOURCE pins will act as an effective heat sink. On double
sided boards (Figure 49), top side and bottom side areas
connected with vias can be used to increase the effective heat
sinking area.
In addition, sufficient copper area should be provided at the
anode and cathode leads of the output diode(s) for heat
sinking.
In Figures 47, 48 and 49 a narrow trace is shown between the
output rectifier and output filter capacitor. This trace acts as a
thermal relief between the rectifier and filter capacitor to
prevent excessive heating of the capacitor.
Quick Design Checklist
As with any power supply design, all TOPSwitch-GX designs
should be verified on the bench to make sure that components
specifications are not exceeded under worst case conditions.
The following minimum set of tests is strongly recommended:
1. Maximum drain voltage – Verify that peak V
2. Maximum drain current – At maximum ambient tempera-
3. Thermal check – At maximum output power, minimum
exceed 675 V at highest input voltage and maximum over-
load output power. Maximum overload output power
occurs when the output is overloaded to a level just before
the power supply goes into auto-restart (loss of regulation).
ture, maximum input voltage and maximum output load,
verify drain current waveforms at start-up for any signs of
transformer saturation and excessive leading edge current
spikes. TOPSwitch-GX has a leading edge blanking time
of 220 ns to prevent premature termination of the on-cycle.
Verify that the leading edge current spike is below the
allowed current limit envelope (see Figure 52) for the drain
current waveform at the end of the 220 ns blanking period.
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
TOP242-250
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