NCP1337ADAPGEVB 60W Adapter Documentation Package Evaluation Board User's Manual http://onsemi.com 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 http://onsemi.com 2 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 http://onsemi.com 3 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 http://onsemi.com 4 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 http://onsemi.com 5 245 265 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 http://onsemi.com 6 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 http://onsemi.com 7 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 http://onsemi.com 8 NCP1337ADAPGEVB BOARD PICTURES http://onsemi.com 9 NCP1337ADAPGEVB SCHEMATIC http://onsemi.com 10 NCP1337ADAPGEVB BOARD LAYOUT Figure 13. Assembly Drawing Figure 14. Global Layer Figure 15. Top Layer http://onsemi.com 11 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 http://onsemi.com 12 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# http://onsemi.com 13 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). 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