60 W Adapter Documentation Package Evaluation Board User's Manual

NCP1337ADAPGEVB
60W Adapter
Documentation Package
Evaluation Board User's
Manual
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EVAL BOARD USER’S MANUAL
Overview
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 adapter; and by judicious choice
of design tradeoffs, optimum performance is achieved at
minimum cost.
This reference document describes a built-and-tested,
GreenPoint solution for a 60 W power adapter.
The reference design circuit consists of one single-sided
100 mm  52 mm printed circuit board. Height is 25 mm.

Figure 1. Circuit Schematic
Introduction
power supply (EPS) add extra constraints in the design of the
adapter.
These requirements target two issues:
 Get rid of the losses in a no load situation (e.g., when
the notebook adapter is plugged in, even when it is not
connected to the computer).
 Achieve a good average efficiency during various active
mode load conditions (25%, 50%, 75% and 100%).
This design using NCP1337 offers a perfect solution for
portable DVD, LCD TV, or monitor and notebook adapter
applications. This adapter provides effective protection
functions such as over-load protection, over-voltage
protection, shortcircuit protection and brown-out
protection. Thanks to the quasi-resonant operation and
synchronous rectifier, this adapter has high efficiency and
improved EMI performance. The standby consumption is
lower because of the cycle skipping and soft ripple mode.
Regulatory requirements addressing low standby power
consumption and efficiency in active mode for external
 Semiconductor Components Industries, LLC, 2013
July, 2013 − Rev. 2
Many regulations have been proposed around the word.
Hereafter is the list of some of the most important ones:
1
Publication Order Number:
EVBUM2075/D
NCP1337ADAPGEVB
1. Energy Star: Applicable in the US and International Partners
 Energy Efficiency Criteria for Active Mode
Nameplate Output Power (Pno)
Minimum Average Efficiency in Active Mode (Expressed as Decimal)
0 to < 1 W
 0.49 * Pno
> 1 and  49 W
 (0.09 * Ln (Pno)) + 0.49
> 49 W
 0.84
 Energy Consumption Criteria for No Load
Nameplate Output Power (Pno)
Minimum Average Efficiency in Active Mode (Expressed as Decimal)
0 to < 10 W
 0.5 W
 10 to  250 W
 0.75 W
2. California Energy Commission:
 Effective January 1, 2007
Nameplate Output
Minimum Efficiency in Active Mode
0 to < 1 W
0.49 * Nameplate Output
> 1 and  49 W
0.09 * Ln (Nameplate Output) + 0.49
> 49 W
0.84
Maximum Energy Consumption in No-Load Mode
0 to < 10 W
0.5 W
 10 to  250 W
0.75 W
Where Ln (Nameplate Output) = Natural Logarithm of the Nameplate Output Expressed in Watts
 Effective July 1, 2008
Nameplate Output
Minimum Efficiency in Active Mode
0 to < 1 W
0.5 * Nameplate Output
> 1 and  51 W
0.09 * Ln (Nameplate Output) + 0.5
> 51 W
0.85
Maximum Energy Consumption in No-Load Mode
Any Output
0.5 W
Where Ln (Nameplate Output) = Natural Logarithm of the Nameplate Output Expressed in Watts
3. European Union Code of Conduct:
 No-load Power Consumption
No-Load Power Consumption
Rated Output Power
Phase 1 (1.1.2005)
Phase 2 (1.1.2007)
> 0.3 W and < 15 W
0.30 W
0.30 W
> 15 W and < 50 W
0.50 W
0.30 W
> 50 W and < 60 W
0.75 W
0.30 W
> 60 and < 150 W
1.00 W
0.50 W
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NCP1337ADAPGEVB
 Energy-Efficiency Criteria for Active Mode for Phase 1 (for the period 1.1.2005 to 31.12.2006)
Rated Output Power
Minimum Four Point Average (see Annex) or 100% Load Efficiency in
Active Mode
0 < W < 1.5
30
1.5 < W < 2.5
40
2.5 < W < 4.5
50
4.5 < W < 6.0
60
6.0 < W < 10.0
70
10.0 < W < 25.0
75
25.0 < W < 150.0
80
 Energy-Efficiency Criteria for Active Mode for Phase 2 (valid after 1.1.2007)
Nameplate Output Power (Pno)
Minimum Average Efficiency in Active Mode (Expressed as Decimal)
(Note 1)
0<W<1
 0.49 * Pno
1 < W < 49
 (0.09 * Ln (Pno)) + 0.49
49 < W < 150
 0.84 (Note 2)
1. “Ln“ refers to the natural logarithm. The algebraic order of operations requires that the natural logarithm calculation be
performed first and then multiplied by 0.09, with the resulting output added to 0.49. (b) An efficiency of 0.84 in decimal
form corresponds to the more familiar value of 84% when expressed as a percentage.
2. Power supplies that have a power factor correction (PFC) to comply with EN61000−3−2 (above 75 W input power) have
a 0.04 (4%) allowance, accordingly the minimum on mode load efficiency (100% or averaged) is relaxed to 0.80 (80%).
4. Korea:
 External Power Supply − No load: 0.8 W
 Battery Charger − No load: 0.8 W
negatively impacted, due to the increase in the complexity
of the design.
This document provides a solution to address the design
challenges brought about by these regulations: requirements
for standby power reduction and active mode energy
efficiency increase at a reasonable cost.
Overcoming Limitations with NCP1337
NCP1337 combines all the requirements for adapter
applications in a spaceefficient SO−7 package. The
NCP1337 combines a true current mode modulator and a
demagnetization
detector,
which
ensures
full
Borderline/Critical Conduction Mode in any load/line
conditions, together with minimum drain voltage switching
(Quasi-Resonant operation). The transformer core reset
detection is done internally, without using any external
signal, due to the Soxyless concept. The frequency is
internally limited to 130 kHz, preventing the controller from
operating above the 150 kHz CISPR−22 EMI starting limit.
By monitoring the feedback pin activity, the controller
enters ripple mode as soon as the power demand falls below
a predetermined level. As each restart is softened by an
internal soft-start, and as the frequency cannot go below
25 kHz, no audible noise can be heard.
The NCP1337 also features an efficient protective circuit
which, in the presence of an overcurrent condition, disables
the output pulses and enters a safe burst mode, trying to
restart. Once the default has gone, the device auto-recovers.
Adapter Requirements
More and more high-power adapters are being used in
high end applications such as LCD monitors, LCD TVs, and
notebook computers. These applications need adapters that
are compliant with world-wide energy regulations, deliver
high efficiency, and provide complete protection functions.
In LCD TV applications, lower radio interference is also
important.
Typically, in these applications, the output power range is
45 W to 60 W. No active PFC is needed. The input is
universal voltage, and the output voltage is around 12 V.
Limitations of Existing Solutions
In many existing solutions, it is difficult to approach a
most optimized design for adapters with minimum parts
count and low cost. Brown out protection, overload
protection with input voltage compensation, latch-off or
disable protection, and soft start function would add about
20 external parts around the controller. Therefore, the
reliability and reproducibility of the adapter would be
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NCP1337ADAPGEVB
Also included is a bulk voltage monitoring function (known
as brown-out protection), an adjustable overpower
compensation, and a VCC OVP. Finally, an internal 4.0 ms
soft-start eliminates the traditional startup stress.
 Overvoltage Protection
 Brown-Out Protection
 Two Externally Triggerable Fault Comparators (one for
The NCP1337 includes the following features:
 Free-Running Borderline/Critical Mode
Quasi-Resonant Operation
 Current-Mode
 Soft Ripple Mode with Minimum Switching Frequency
for Standby
 Auto-Recovery Short-Circuit Protection Independent of
Auxiliary Voltage







a disable function, and the other for a permanent latch)
Internal 4.0 ms Soft-Start
500 mA Peak Current Drive Sink Capability
130 kHz Maximum Frequency
Internal Leading Edge Blanking
Internal Temperature Shutdown
Direct Optocoupler Connection
Dynamic Self-Supply with Levels of 12 V (On) and
10 V (Off)
Table 1. SPECIFICATIONS
Parameter
Test Condition
Min
Typ
Max
Unit
Voltage Range
90
−
265
Vac
Frequency Range
47
−
63
Hz
Brown Out Threshold
65
−
75
Vac
Brown Out Hysteresis
−
10
−
Vac
INPUT
Input Inrush Current
Cold Start 230 Vac
−
−
65
A
No-load Input Power
Input 240 Vac
−
−
0.3
W
−
12
−
V
OUTPUT
Output Voltage
Voltage Total Regulation
90 Vac to 265 Vac Input and 0 to 5 A Output
−
−
2
%
Load Output Current
90 Vac to 265 Vac
0
−
5
A
Start-up Overshoot
90 Vac to 265 Vac
−
−
10
%
Transient Regulation
2.5 A to 5 A Step
−
−
300
mV
Transient Recovery Time
2.5 A to 5 A Step; Recovery to 1%
−
−
200
ms
Ripple
20 MHz Bandwidth, Full Load
−
−
100
mV
Over Current Protection
90 Vac to 265 Vac
5.5
−
7
A
Over Voltage Protection
Open Voltage Feedback Loop
13.5
14
14.5
V
−
−
60
W
TOTAL OUTPUT POWER
Continuous Output Power
Total Power
Conducted EMI Margin
EN55022 Class B
6
−
−
dB
Efficiency
Input 230 Vac, Full Load
88
−
−
%
Operation Temperature
Full Load, Free Air Convection Cooling
0
−
40
C
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NCP1337ADAPGEVB
REFERENCE DESIGN PERFORMANCE
No−Load Input Power
(By YOKOGAWA WT210)
300
250
200
150
100
50
50
100
150
200
250
300
Input Voltage (Vac)
Figure 2. No−Load Consumption,
Output Voltage 12.25 V, Output Current 0 A
Low−Load Input Power
(By YOKOGAWA WT210)
1000
950
900
850
800
750
700
50
100
150
200
250
300
Input Voltage (Vac)
Figure 3. Low Load 0.5 W Consumption,
Output Voltage 12.25 V, Output Current 42 mA
Efficiency (%)
Efficiency
90.00
89.00
88.00
87.00
86.00
85.00
84.00
83.00
82.00
81.00
80.00
Efficiency
85
105
125
145
165
185
205
225
Input (Vac)
Figure 4. Efficiency vs Input Voltage at Full Load
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245
265
NCP1337ADAPGEVB
REFERENCE DESIGN PERFORMANCE
Efficiency
Efficiency (%)
90.00
80.00
70.00
60.00
50.00
40.00
30.00
Efficiency
20.00
10.00
0.00
0
5
10
15
20
25
30
35
40
45
50
55
60
Load (Watt)
Figure 5. Efficiency vs Load at 110 Vac Input
Efficiency
Efficiency (%)
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
Efficiency
0.00
0
5
10
15
20
25
30
35
40
45
Load (Watt)
Figure 6. Efficiency vs Load at 220 Vac Input
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50
55
60
NCP1337ADAPGEVB
REFERENCE DESIGN PERFORMANCE
90 Vac Input, Switching Frequency 31 kHz
250 Vac Input, Switching Frequency 92 kHz
Figure 7. Voltage Waveform of MOSFET Q2 Drain @ Full Load
90 Vac Input, CH1 Vgs, CH2 Vds
250 Vac Input, CH1 Vgs, CH2 Vds
Figure 8. Drive Waveform of MOSFET Q1 (Synchronous Rectifier) @ Full Load
90 Vac Input, Over Load at 5.5 A, CH1 Vds, CH2 Vcc
250 Vac Input, Over Load at 5.9 A, CH1 Vds, CH2 Vcc
Figure 9. VDS of Q2 and VCC Waveform @ Over Load
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NCP1337ADAPGEVB
REFERENCE DESIGN PERFORMANCE
Input Voltage 90 Vac
Input Voltage 250 Vac
Figure 10. Dynamic Load Transient Response @ Step Load 2.5 A to 5 A to 2.5 A
CH1: BO Pin, CH2: Output (OVP 13.91 V)
Figure 11. Over Voltage Protection (Voltage Feedback Open Circuit Mode) @ Full Load
110 Vac Input
220 Vac Input
Figure 12. EMI @ Full Load
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NCP1337ADAPGEVB
BOARD PICTURES
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NCP1337ADAPGEVB
SCHEMATIC
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NCP1337ADAPGEVB
BOARD LAYOUT
Figure 13. Assembly Drawing
Figure 14. Global Layer
Figure 15. Top Layer
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NCP1337ADAPGEVB
BOARD LAYOUT
Figure 16. Bottom Layer
Table 2. BILL OF MATERIALS
Item
Quantity
Reference
Part
1
1
C1
2.2 nF/Y1
2
2
C2, C3
2200 mF, 16 V
3
1
C4
470 mF, 16 V
4
1
C5
4.7 nF, 1 kV
5
1
C6
0.22 mF/X2
6
1
C7
150 mF, 400 V
7
1
C8
10 nF, 1 kV
8
1
C9
2.2 nF, 100 V
9
1
C10
1 nF, 50 V
10
4
C11, C13, C14, C16
0.1 mF, 50 V
11
1
C12
47 mF, 25 V
12
1
C15
100 pF, 50 V
13
1
D1
GBU608
14
1
D2
MBR160
ON Semiconductor
15
1
D3
1N4937
ON Semiconductor
16
3
D4, D7, D8
MMSD4148
ON Semiconductor
17
1
D5
MMSZ13
ON Semiconductor
18
1
D6
MMSZ15
ON Semiconductor
19
1
F1
T3A250VAC
20
1
L1
1.8 mH, 5A
21
1
L2
75 mH
22
1
L3
150 mH
23
1
L4
20 mH
24
1
Q1
NTP75N06
ON Semiconductor
25
4
Q2, Q5, Q6, Q8
MMBT3906L
ON Semiconductor
26
1
Q3
9 A, 650 V
27
2
Q4, Q7
MMBT3906L
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Manufacturer
ON Semiconductor
NCP1337ADAPGEVB
Table 2. BILL OF MATERIALS
Item
Quantity
Reference
Part
28
1
R1
5 W NTC
29
4
R2, R6, R10, R19
1MW
30
1
R3
MOV471
31
1
R4
47kW/1 W
32
1
R5
4.7 W
33
3
R7, R15, R18
2 kW
34
4
R8, R22, R26, R31
5.1 kW
35
4
R9, R20, R29, R32
10 kW
36
2
R11, R23
10 W
37
5
R12, R14, R16, R24, R25
1 kW
38
1
R13
15 kW
39
1
R17
20 kW
40
1
R21
27 W
41
1
R27
2.4 kW
42
1
R28
9.1 kW
43
1
R30
0.18 W/1 W
44
1
T1
PQ3220
45
1
T2
CT1:100 Toroid or UU9.8
46
2
U1, U2
PC817C
47
1
U3
NCP1337
ON Semiconductor
48
1
U4
TL431A
ON Semiconductor
49
1
PCB
PCB5.2*10
Appendix
Top Runner (Japan):
 http://www.eccj.or.jp/top_runner/index.html
Product Information
EU Eco-label (Europe):
 http://europa.eu.int/comm/environment/ecolabel/index_
en.htm
 http://europa.eu.int/comm/environment/ecolabel/produc
t/pg_portablecomputers_en.htm
 NCP1337 Quasi Resonant Controller featuring Over









Manufacturer
Power Compensation
TL431A Programmable Precision Reference
1N4937 Fast-Recovery Rectifier, 1 A, 600 V
MBR160 Schottky Rectifier, 1 A, 60 V
MMBT3904L General Purpose Transisitor, NPN
MMBT3906L General Purpose Transisitor, PNP
MMSD4148 Switching Diode
MMSZ13 Zener Diode, 500 mW, 13 V
MMSZ15 Zener Diode, 500 mW, 15 V
NTP75N06 Power MOSFET, 75 A, 60 V
EU Code of Conduct (Europe):
 http://energyefficiency.jrc.cec.eu.int/html/standby_initia
tive.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=ext_power_sup
plies.power_supplies_consumers
References
CECP (China):
 http://www.cecp.org.cn/englishhtml/index.asp
1 Watt Executive Order:
 http://oahu.lbl.gov/
 http://oahu.lbl.gov/level_summary.html
Energy Saving (Korea):
 http://weng.kemco.or.kr/efficiency/english/main.html#
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NCP1337ADAPGEVB
Transformer Specification
LP (W1 + W4) = 600 mH 7% @ 10 kHz 1 V
Leaking Induction: 60 mH max
CORE: PQ32−20
Pin1
Pin10,11,12
W2,W5
W4
Secondary Side
Pin7,8,9
Pin2
W1
Primary Side
Pin3
Pin4
W3
Pin5
T1
PQ3220
GreenPoint is a registered trademark of Semiconductor Components Industries, LLC (SCILLC).
ON Semiconductor and
are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC owns the rights to a number of patents, trademarks,
copyrights, trade secrets, and other intellectual property. A listing of SCILLC’s product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent−Marking.pdf. SCILLC
reserves the right to make changes without further notice to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any
particular purpose, nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without
limitation special, consequential or incidental damages. “Typical” parameters which may be provided in SCILLC data sheets and/or specifications can and do vary in different applications
and actual performance may vary over time. All operating parameters, including “Typicals” must be validated for each customer application by customer’s technical experts. SCILLC
does not convey any license under its patent rights nor the rights of others. SCILLC products are not designed, intended, or authorized for use as components in systems intended for
surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the SCILLC product could create a situation where
personal injury or death may occur. Should Buyer purchase or use SCILLC products for any such unintended or unauthorized application, Buyer shall indemnify and hold SCILLC and
its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly,
any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that SCILLC was negligent regarding the design or manufacture
of the part. SCILLC is an Equal Opportunity/Affirmative Action Employer. This literature is subject to all applicable copyright laws and is not for resale in any manner.
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EVBUM2075/D
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