
AN-30
20
B
12/02
′
limit of the 
TOPSwitch-GX
 is sufficient for all the specified
conditions.
Check that the transformer does not saturate under all steady-
state combinations of line and load. Verify the proper design of
the circuit to limit maximum duty ratio with the procedure in
Appendix B.
Check the ripple on all the output voltages with several
combinations of input voltage and output loading, particularly
if the design uses a coupled inductor.  Verify that the under-
voltage thresholds are within design limits for startup and for
shutdown.
Key Design Considerations
While the design of forward converters with 
TOPSwitch-GX
has much in common with designs that use discrete transistors
and controllers, some important differences must be considered.
Attention to these items will significantly reduce the time to
arrive at a successful design.
 A proper clamp circuit is required to control the maximum
drain voltage.  Resonant clamp circuits are not recommended.
While the example clamp circuit in this document is suitable
for moderate power levels, the circuit will need modification
to adapt to applications that require the dissipation of more
power.
 Leakage inductance of the transformer affects the power
dissipation in the clamp circuit.  High leakage inductance
will prohibit the use of simple clamp circuits.  Be aware that
a magnetic amplifier post regulator will greatly increase the
effective leakage inductance of the transformer.
 The primary inductance of the transformer affects the power
dissipation in the clamp circuit.  Maximize the primary
inductance to reduce the magnetizing current and the energy
that must be processed by clamp circuit.
 Use a slow diode for the rectifier D1 in the clamp circuit.  A
fast diode will greatly increase the amount of energy that the
clamp must dissipate.
 Remember that the components R
 and C
 on the secondary
are important components of the clamp circuit.  Failure to
include this network will cause excessive power dissipation
in the clamp components on the primary.
 Confirm in bench evaluations that C
 in the clamp circuit on
the primary is not too large.  Perform transient load tests at
low and high input voltages.  Monitor the drain voltage
waveform for volt-second balance to be certain that the
transformer does not saturate.
 Check the temperature of the Zener diodes VR1, VR2 and
VR3 in the clamp circuit under maximum load at low input
voltage and with repetitive transient loading.  If the power
supply does not have a latching shutdown for fault conditions,
check it under a sustained short circuit on the output.  There
could be excessive heating if C
 is too small, the primary
inductance of the transformer is too low, or if the leakage
inductance it too high.
 Match the current limit to the load.  Use the X pin to program
the current limit lower, especially if a larger 
TOPSwitch-GX
is selected for thermal or efficiency reasons.
References
[1] R. W. Erickson and D. Maksimovic, Fundamentals of
Power Electronics, Second Edition.  Kluwer Academic
Publishers, 2001.  ISBN 0-7923-7270-0.
[2] Colonel Wm. T. McLyman, Transformer and Inductor
Design Handbook, Second Edition.  Marcel Dekker, Inc., 1988.
ISBN 0-8247-7828-6.
[3] Colonel Wm. T. McLyman, Magnetic Core Selection for
Transformers and Inductors, A User’s Guide to Practice and
Specification, Second Edition.  Marcel Dekker, Inc, 1997.
ISBN 0-8247-9841-4.
[4] Colonel W. T. McLyman, Designing Magnetic Components
for High Frequency dc-dc Converters.  Kg Magnetics, Inc.,
1993.  ISBN 1-883107-00-8.
[5] Micrometals Inc., 5615 E. La Palma Avenue, Anaheim, CA
92807 USA; 
www.micrometals.com
.
[6] MAGNETICS, P.O. Box 391, Butler, PA 16003-0391 USA,
www.mag-inc.com
.