TND315/D Rev. 1, Mar-06 160 W CRT-TV Power Supply Documentation Package Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 1 TND315/D © 2006 ON Semiconductor. Disclaimer: ON Semiconductor is providing this reference design documentation package “AS IS” and the recipient assumes all risk associated with the use and/or commercialization of this design package. No licenses to ON Semiconductor’s or any third party’s Intellectual Property is conveyed by the transfer of this documentation. This reference design documentation package is provided only to assist the customers in evaluation and feasibility assessment of the reference design. It is expected that users may make further refinements to meet specific performance goals. Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 2 TND315/D 1 2 3 4 Overview.......................................................................................................4 Introduction ...................................................................................................5 CRT-TV Power Supply Requirements ..........................................................6 Limitations of existing solutions ....................................................................6 4.1 Achieve 1 W with 1 PSU.........................................................................6 4.2 Audible noise ..........................................................................................6 5 Overcoming limitations with NCP1337..........................................................7 5.1 Quasi resonant operation .......................................................................7 5.2 Secondary reconfiguration......................................................................7 5.3 Standby mode ........................................................................................7 6 Specifications................................................................................................8 7 Reference Design Performance Summary ...................................................8 7.1 Efficiency ................................................................................................8 7.2 Standby Power .......................................................................................8 8 Board Picture ................................................................................................9 9 Schematic ...................................................................................................10 10 Board Layout ..............................................................................................10 11 BOM ...........................................................................................................11 12 Appendix.....................................................................................................12 Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 3 TND315/D 1 Overview This reference document describes a built-and-tested, GreenPointTM solution for a CRT TV power supply. The reference design circuit consists of one single-sided 163 mm x 80 mm printed circuit board designed to fit into a CRT TV. An overview of the entire circuit is provided by Figure 1. As shown in that figure, ON Semiconductor devices are available for every block of the CRT TV power supply; and by judicious choice of design tradeoffs, optimum performance is achieved at minimum cost. Figure 1 Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 4 TND315/D 2 Introduction Energy efficiency has become one of the most important policy areas. The energy consumption of consumer electronics equipment, while in standby mode, is huge. Recent studies and in situ measurement campaigns have indicated that in the average EU household between 5% and 10% of its total yearly electricity consumption is due to the stand-by mode of consumer electronics equipment and other devices, and this is due to increase in the next decade. TV sets are obviously one of the biggest contributors. According to EPA, the bill Americans pay to supply their TVs and VCRs when they are switched off is $1 billion each year. In 1997, the European Commission concluded a negotiated agreement with individual consumer electronics manufacturers and the EU trade association EACEM, to reduce the stand-by losses of TVs and VCRs. In the year 2003 a new agreement for TVs and DVDs was concluded. Since then many initiatives have been taken around the word. Even if these requirements are not yet standards, most of the manufacturers have already applied these rules in their designs. Hereinafter the list of the most important initiatives: Region / Country China European Union European Union Europe Program name CECP Energy Saving EU EcoLabel EU Code of Conduct GEEA US Energy Star US 1 Watt Executive Order Korea Requirements for Televisions 3W Demoboard compliance Yes 3W Yes 1W 9 W with a STB Yes 3 W with a STB Yes 1W 1 W to 15 W New revision on going Yes 1W Yes Yes This reference document describes a solution for a CRT TV power supply based on the NCP1337 that allows compliance with the most stringent requirements, using a single power supply. Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 5 TND315/D 3 CRT-TV Power Supply Requirements Most of the CRT Power supplies are designed to cope with universal mains: 90 Vac to 265 Vac, 47-63 Hz. In any CRT, the tube needs to be supplied by a high voltage rail, generally between 110 and 140 V. The microcontroller and the memory use 3.3 V and 5 V that derive from an intermediate 8 V. Audio ICs are often supplied from 12 V and 20 V. Tuner can be supplied from 12 V or a 5 V. 4 Limitations of existing solutions 4.1 Achieve 1 W with 1 PSU The classical technique consisting of disabling the secondary loads while keeping the power supply running can no longer be used. In fact, even in a disabled mode the loads are generally presenting some hundred milliwatts of leakage. This is the case in TV sets. A solution to cancel this leakage consists of totally disconnecting the loads, but it is expensive and can lead to some issues when the fault conditions tests are performed. Another technique consists of completely disabling the main power supply during the stand-by mode, and of installing a micropower side-power supply to keep ready to work the wake-up block. This is also not a preferred solution for obvious cost reasons. 4.2 Audible noise One of the issues faced by the classical solutions is audible noise. Since a TV sets can be placed in a very quite environment (e.g.: bed room, living room) any whistling noise would be dramatic. Classical burst mode operation can easily generate some noise. Solving this noise issue made the power supply design more difficult and may interfere with the wish of achieving very low standby power consumption. Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 6 TND315/D 5 Overcoming limitations with NCP1337 5.1 Quasi resonant operation Valley switching converters, also known as quasi resonant (QR) converters, allow designing flyback Switch Mode Power Supplies (SMPS) with reduced Electromagnetic Interference (EMI) signatures and improved efficiency compared to a classical fixed frequency flyback approach. Thanks to the low level of generated noise, valley switching SMPS converters are therefore very well suited to applications dealing with RF and video signals, such as TVs. The NCP1337 is a powerful valley switching controller, which eases the design of an EMI−friendly TV power supply with only a few surrounding components. Valley-switching operation is ensured whatever the operating conditions are, due to the internal soxyless circuitry. As a result, there are virtually no primary switch turn-on losses, and no secondary diode recovery losses, and EMI and video noise perturbations are reduced. The converter also stays a first-order system and accordingly eases the feedback loop design. 5.2 Secondary reconfiguration We choose to use a secondary reconfiguration that, by re-routing the high voltage winding to the low voltage output, reduces the voltage of all the unused outputs. In fact, the energy stored in the high voltage winding is used to refuel the low voltage output capacitor, and regulation is now made on this low voltage output. As the windings are imposing currents (not voltages), connecting a high voltage winding to a low voltage output is completely safe. But as the regulation loop now forces the high voltage winding to deliver a low voltage, then all the other windings are also delivering lower voltages than in normal conditions (in the same ratio). The sum of the consumptions on all the windings is drastically reduced due to this division of all the output voltages. 5.3 Standby mode Under low load conditions, NCP1337 enters a soft ripple mode: when the CS setpoint becomes lower than 20% of the maximum peak current, output pulses are stopped; then switching is started again when FB loop forces a setpoint higher than 25%. As this occurs at low peak current, with soft-skip activated, and as the TOFF is clamped, noise-free operation is guaranteed, even with a cheap transformer. Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 7 TND315/D 6 Specifications Input Voltage: Universal input 90 Vac to 265 Vac, 47-63 Hz Outputs: +135 V, 1 A max (135 W) regulated +20 V, 800 mA max (16 W) +12 V, 500 mA max (6 W) +8 V, 500 mA max (4 W) Standby output : +5 V, 100 mA derived from +8 V through a regulator Protections Short-circuit, over-power, over-voltage and brown-out Standby Power below 1 W 7 Reference Design Performance Summary 7.1 Efficiency • • At 230 Vac, 148 W IN for 135 W OUT At 110 Vac, 154 W IN for 135 W OUT 91% 87% 7.2 Standby Power Noise-free operation is achieved during standby mode. All outputs are low (135 V output is 12.7 V), except 5 V standby output which is maintained. IOUT consumption is taken on 5 V standby output. Controller is powered thanks to the Dynamic Self-Supply (DSS). All outputs are low (135 V output is 12.7 V), except 5 V standby output which is maintained. IOUT consumption is taken on 5 V standby output. Controller is powered thanks to a forward-coupled auxiliary winding. Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 8 TND315/D All outputs are at their nominal values. IOUT consumption is taken on 5 V standby output. Controller is powered thanks to the auxiliary winding. 8 Board Picture Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 9 TND315/D 9 Schematic 10 Board Layout Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 10 TND315/D 11 BOM Designator IC1 IC2 IC3 IC4 X1 M1 Q1 T1 Part Number NCP1337PG TL431CLP SFH615A MC78L05ACP IRFIB6N60A BS108G BC547C SRW42/15EC−X21V017 BCK4201−304 47283900 RM4 218002 KBU4K 1N4007 L1 F1 D1 D5, D10, D14, D16, D141 D6 1N4937 D7 MMSD4148T1 D11, D12, D111 MUR420 D13 MUR460 DZ2 1N5335B DZ3 1N5341B R1, R35 CCF551K00FK R2 PR02000204702J Rbo CCF552M74FK Rbo1 CCF551M21FK Rbo2 CCF5515K0FK Rhyst R3 CCF5547R5FK R4 CCF5515R0FK R5, R21 CCF5533K2FK Rs1, Rs2 LVR03R1500FS70 R6 CCF552K21FK R7 VR370000106JA1 R8 CCF60332RFK R10 CCF60150KFK R11 CCF55121KFK R12 CCF555K62FK R13, R16 CCF55100KFK R17 R18, R31 CCF5518K2FK R19 CCF551K50FK R33,R34 CCF5547K5FK P1 T93YB102K C1,C2 R73PI 2330DQ0-J C3 5AS100JABCG C4 ESMM451VSN221MQ40S C5 C7 R82DC4100DQ6-J C8 R60PF2100DQ6-M C9 C10 ECEA1EN330U C11, C13, C15, TGP10 C25, C131 C12 5SS331KABAA C14,C16, C141 ECA1VM102 C17 ECA1EM101 C18 ECA1CM102 C20 ECA2DM101 C21 TSD10 C23 WKP222 C430C474M5U5CA7200 C26 H1 1718029 H2 1890963 H3 1890976 Supplier ON Semiconductor ON Semiconductor Vishay ON Semiconductor IR ON Semiconductor ON Semiconductor TDK CLICK OREGA Littelfuse Vishay ON Semiconductor Description Enhanced Current−Mode Controller Programmable Precision Reference Optocoupler, High Reliability Positive Voltage Regulator HEXFET Power MOSFET Small Signal MOSFET NPN Transistor Transformer Value NA 2.5 - 36 V, 1-100 mA 5300 VRMS 5 V, 100 mA 600 V, 5.5 A 200 V, 250 mA NA NA Tolerance NA 2.2% NA 5% NA NA NA Package PDIP-7 TO-92 DIP-4 TO-92 TO-220 TO-92 TO-92 NA Comon mode choke Fuse Bridge Rectifier Standard Rectifier NA 250 V, 2 A 800 V, 4 A 1000 V, 1 A NA NA NA NA NA 5 x 20 (mm) KBU Axial ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Vishay Arcotoronics AVX Nippon Chemicon Arcotronics Arcotronics Panasonic Vishay Fast-Recovery Rectifier Small Signal Switch Diode Ultrafast Rectifier Ultrafast Rectifier 5 W Zener Diode 5 W Zener Diode Metal Film resistor R0204 Metal Film resistor 2W (PR2) Metal Film resistor Metal Film resistor Metal Film resistor Not Mounted Metal Film resistor Metal Film resistor Metal Film resistor Low value resistor Metal Film resistor High Ohmic, High Voltage Resistor Metal Film resistor Metal Film resistor Metal Film resistor Metal Film resistor Metal Film resistor Not Mounted Metal Film resistor Metal Film resistor Metal Film resistor 3/8” Square Multi-Turn Cermet Trimmer X2 Polypropylene Capacitor Ceramic Disc Capacitor Not Mounted Electrolytic Capacitor Polyester Capacitor Polyester Capacitor Not Mounted Electrolytic Capacitor Ceramic Capacitor 600 V, 1 A 100 V, 200 mA 200 V, 4 A 600 V, 4 A 3.9 V, 320 mA 6.2 V, 200 mA 1 kΩ, 0.5 W 47 kΩ, 2 W 2.7 MΩ, 0.5 W 1.2 MΩ, 0.5 W 15 kΩ, 0.5 W 47 Ω, 0.5 W 15 Ω, 0.5 W 33 kΩ, 0.5 W 0.15 Ω 2.2 kΩ, 0.5 W 10 MΩ, 0.5 W 330 Ω, 0.75 W 150 kΩ 120 kΩ, 0.5 W 5.6 kΩ, 0.5 W 100 kΩ, 0.5 W 18 kΩ, 0.5 W 1.5 kΩ, 0.5 W 47 kΩ, 0.5 W 1 kΩ, 0.5 W 0.033 uF, 300 Vac 10 pF, 2 kV 220 uF, 450 V 1 uF, 63 V 10 nF, 630 V 33 uF, 25 V 100 nF, 100 V NA NA NA NA NA NA 1% 5% 1% 1% 1% 1% 1% 1% 1% 1% 5% 1% 1% 1% 1% 1% 1% 1% 1% 10% 5% 5% 20% 5% 20% 20% 20% Axial SOD-123 Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial Axial NA Box Disc Radial Box Box Radial Disc AVX Panasonic Panasonic Panasonic Panasonic AVX Vishay Kemet Phoenix Contact Phoenix Contact Phoenix Contact Ceramic Capacitor Electrolytic Capacitor Electrolytic Capacitor Electrolytic Capacitor Electrolytic Capacitor Ceramic Capacitor Y1 Ceramic Capacitor Ceramic Capacitor PCB Connector PCB Connector PCB Connector 330 pF, 2 kV 1000 uF, 35 V 100 uF, 25 V 1000 uF, 16 V 100 uF, 200 V 1 nF, 100 V 2.2 nF, 500 Vac 470 nF, 50 V NA NA NA 10% 20% 20% 20% 20% 10% 20% 20% NA NA NA Disc Radial Radial Radial Radial Axial Disc Axial NA NA NA Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 11 TND315/D 12 Appendix References: • Draft Commission Communication on Policy Instruments to Reduce Stand-by Losses of Consumer Electronic Equipment (19 February 1999) o http://energyefficiency.jrc.cec.eu.int/pdf/consumer_electronics_com munication.pdf • European Information & Communications Technology Industry Association o http://www.eicta.org/ • http://standby.lbl.gov/ACEEE/StandbyPaper.pdf CECP (China): • http://www.cecp.org.cn/englishhtml/index.asp Energy Saving (Korea) • http://weng.kemco.or.kr/efficiency/english/main.html# Top Runner (Japan): • http://www.eccj.or.jp/top_runner/index.html EU Eco-label (Europe): • http://europa.eu.int/comm/environment/ecolabel/index_en.htm • http://europa.eu.int/comm/environment/ecolabel/product/pg_television_en. htm EU Code of Conduct (Europe): • http://energyefficiency.jrc.cec.eu.int/html/standby_initiative.htm GEEA (Europe): • http://www.efficient-appliances.org/ • http://www.efficient-appliances.org/Criteria.htm Energy Star: • http://www.energystar.gov/ • http://www.energystar.gov/index.cfm?c=product_specs.pt_product_specs 1 Watt Executive Order: • http://oahu.lbl.gov/ • http://oahu.lbl.gov/level_summary.html Additional collateral from ON Semiconductor • AND8246/D, A 160 W CRT TV Power Supply Using NCP1337 • NCP1337 Semiconductor Components Industries, LLC, 2006 March, 2006 – Rev 1 12 TND315/D ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). 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