160 W CRT TV Power Supply GreenPoint Reference Design

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.
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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
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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
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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.
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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.
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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.
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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.
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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
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9 Schematic
10 Board Layout
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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
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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
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TND315/D
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