Designing Converters with the NCP101X Family

AND8134/D
Designing Converters with
the NCP101X Family
Prepared by: Christophe Basso
ON Semiconductor
http://onsemi.com
APPLICATION NOTE
For moderate power offline applications, a monolithic
circuit, such as the NCP101X series, represents a pertinent
choice for engineers looking for design speed and ease of
implementation. Incorporating everything needed to build
reliable and safe Switch−Mode Power Supplies (SMPS), the
NCP101X combines a current−mode controller and a 700 V
power MOSFET. Due to ON Semiconductor proprietary
high−voltage technology, the device directly supplies itself
from the rectified mains and, in numerous cases, does not
need an auxiliary winding to operate. This application note
details the internal circuit operation and gives tricks to make
your design successful.
• Fail−Safe Optocoupler and OVP: When an auxiliary
The Specs at a Glance
The NCP101X capitalizes on the successful NCP1200
series where the words compactness and flexibility could
both be applied to qualify the controller philosophy. In this
particular version, the controller looks very similar to that of
the 1200 but a 700 V lateral MOSFET has been added to the
part. Let’s quickly browse its features:
• No Need of Auxiliary Winding: ON Semiconductor’s
Very High Voltage Integrated Circuit technology lets
you supply the IC directly from the high−voltage DC
rail. We call it Dynamic Self−Supply (DSS) and was
already implemented in the 1200 series. This solution
simplifies the transformer design and ensures a better
control of the SMPS in difficult output conditions, e.g.
constant current operations or overload. However, for
improved standby performance, an auxiliary winding
can be connected to the Vcc pin to disable the DSS
operation.
• Short−Circuit Protection: By permanently monitoring
the feedback line activity, the IC is able to detect the
presence of a short−circuit, immediately reducing the
output power for a total system protection. Once the
short has disappeared, the controller resumes and goes
back to normal operation.
•
 Semiconductor Components Industries, LLC, 2003
October, 2003 − Rev. 0
•
•
1
winding is connected to the Vcc pin, the device stops its
internal Dynamic Self−Supply and takes its operating
power from the auxiliary winding. An 8.7 V active
clamp is connected between Vcc and ground. In case
the current injected in this clamp exceeds a level of
around 7.4 mA typ., the controller immediately latches
off and stays in this position until the user cycle Vcc
down to 3.0 V (e.g. unplugging the converter from the
wall). By adjusting a limiting resistor in series with the
Vcc terminal, it becomes possible to implement an over
voltage protection function, latching off the circuit in
case of broken optocoupler or feedback loop problems.
Low Standby−Power: If SMPS naturally exhibit a
good efficiency at nominal load, they begin to be less
efficient when the output power demand diminishes. By
skipping unneeded switching cycles, the NCP101X
drastically reduces the power wasted during light load
conditions. An auxiliary winding can further help
decreasing the standby power to extremely low levels
by invalidating the DSS operation. In that case,
experience shows that a standby power below 100 mW
at 230 VAC is achievable.
No Acoustic Noise While Operating: Instead of
skipping cycles at high peak currents, the NCP101X
waits until the peak current demand falls below a fixed
1/4 of the maximum limit. As a result, cycle skipping
can take place without having a singing transformer.
You can thus select cheap magnetic components free
of noise problems.
SPICE Model: A dedicated model to run transient
cycle−by−cycle simulations is available but also
an averaged version to help you closing the loop.
Ready−to−use templates can be downloaded in
OrCAD’s PSpice, and INTUSOFT’s IsSpice4 from
ON Semiconductor’s web site, NCP101X related
section.
Publication Order Number:
AND8134/D
AND8134/D
The Dynamic Self−Supply
A Dynamic Self−Supply (DSS) offers an easy means to
provide power to the control section, without using an
auxiliary winding. The DSS consists in a current source
connected to the swinging high−voltage drain, and operated
on or off depending on the Vcc level: if the Vcc is below a
given value, the source is on and Vcc rises up. When Vcc has
reached the desired value, the source turns off, and no longer
consumes power. This system is self−regulated and works as
a hysteretic regulator: if the consumption increases, the
current source will stay on longer and the off period will
shorten. As a result, the DSS being connected to the drain,
the average current taken from that path, reflects the average
current drawn from the Vcc pin (neglecting the DSS
operation losses). Figure 1 depicts the way the DSS is
implemented and Figure 2 portrays its typical operating
signals.
From
Bulk
5 Drain
Start−Up Time
9.00
8.5 V
7.5 V
+
8V
Avg.
8.5 V
Current
Source
ON = 7 mA
OFF = 0
+
−
7.5 V
7.00
Error Flag Test is Here
5.00
1
Source is ON
Vcc
Source
is OFF
3.00
+
Current
Reading
1.00
8
Gnd
16.6m
49.9m
83.2m
116m
150m
Figure 1. The internal supply implementation . . .
Figure 2. . . . and its typical operating signals, like
the Vcc ripple.
The DSS up and down slopes are internally used as timers
to eventually detect an error condition, e.g. an overload
event. When the feedback level is pushed to the maximum,
an active clamp starts to operate and limits the current, cycle
by cycle. This active clamp is nothing else than the usual
1.0 V “zener” you find in the NCP120X series, except that
the clamping level is smaller in the NCP101X series. As
soon as this clamp is activated, it asserts a digital flag,
testifying for an overload condition or a loss of the feedback
signal. When the Vcc logic senses that 7.5 V is reached AND
that the error flag is asserted, the logic stops pulses and
enters a safe, auto−recovery, burst mode. As soon as the error
goes away, the SMPS resumes its operation.
Overload events always happen during the start−up
sequence where the controller strives to grow Vout. During
that time, the loop pushes the peak current to the maximum
(hence the clamp activation) and waits until Vout reaches the
target. The time given by the controller to let the supply
build−up Vout corresponds to the first downslope (see
Figure 2). If the error flag is still high at the first 7.5 V event,
then the controller activates the burst. As a result, it is
important to check with the oscilloscope that the device
regulates before the first 7.5 V event. This can be done by
monitoring the FB pin (pin4) and the Vcc pin (pin1). As
Figure 3 indicates, a proper dimensioning of CVcc implies
a FB release before the end of the downslope.
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AND8134/D
Pulses Start
Error Check
VCC
Feedback
Power ON
FB is released
before check.
No error . . .
Figure 3. The release of the FB pin before the first 7.5 V event
indicates that the supply has enough time to start−up.
EMI Jittering Using the Vcc
The ripple excursion that you notice on the Vcc is
internally used to modulate the switching frequency of the
PWM controller. Typically, a 3.3% deviation is observed for
a Vcc sweep between VccON and VccOFF, e.g. 62.8 kHz @
7.5 V up to 67.2% @ 8.5 V typically for a 65 kHz reference.
This so−called frequency jittering lowers the EMI peaks at
Fsw and its following harmonics.
Fsw x Hx
L1
Without Jittering
A1
L2
With Jittering
A2
L1avg L2avg
A1 = A2
Figure 4. Frequency Jittering Spreads the Energy Content and Lowers Discrete Peaks
reduced by the low frequency modulation. As a result, less
efforts are needed on the input filter design.
Connecting an auxiliary winding to the Vcc disables the
frequency modulation since the DSS ripple fades away.
The jittering actually performs a so−called spread
spectrum modulation which “spreads” the energy to
adjacent frequencies rather than inside a single ray. When
the EMI receiver opens it’s narrow filter window at a given
frequency F1, the accumulated (averaged) energy at F1 is
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AND8134/D
The DSS and the Duty−Cycle
In the NCP101X series, the current source is connected to
the drain node, unlike the 120X family where it was tied to
the DC bulk rail. As a result, the current source “sees” a
swinging node affected by a large dV/dt with voltage
excursions from almost ground (MOSFET is ON) up to
nearly 700 V (MOSFET is OFF). This situation can
sometimes affect the DSS behavior, especially if the
duty−cycle exceeds 45%. In that case, the voltage necessary
to operate the source is too low and the available current
cannot refuel the Vcc capacitor. Why, since the average
voltage across Lp being null, the current source should face
a similar situation as when connected to the bulk? In reality,
the pulse frequency makes the situation difficult for the
current source, a high−voltage MOSFET, that needs to be
quickly turn−on during the OFF time only. At a certain point,
if the duty−cycle is too large, the DSS voltage starts to bend
before stopping its hysteretic regulation. Figure 5 portrays
typical curves where the duty−cycle expands toward 50%
and engenders the DSS bending. Should the duty−cycle
further increase, the DSS would stop (the Vcc simply
flattens) but the IC would still continue to operate.
Duty−Cycle 45%
Duty−Cycle 45%
DSS Bends
DSS ok
Figure 5. When the duty−cycle exceeds 45%, the DSS starts to bend, indicating the beginning
of the limit for the DSS.
• If necessary, grow−up the bulk capacitor to reduce the
To take the full benefit of the DSS, here are some
recommendations that need to be understood for a
successful design:
• Design for a steady−state duty−cycle smaller than 45%
at minimum input voltage and maximum load. It is not
a problem that transient duty−cycles exceed that limit,
e.g. during load variations. The NCP101X can work in
both DCM and CCM without problem.
ripple at low line and thus increase the available
rectified DC voltage in worse input case.
Be sure to test your final design at the right ambient
temperature while observing the Vcc ripple. A slightly bent
ripple as on Figure 4 is not a problem if observed at high
ambient temperatures.
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AND8134/D
Internal
Vcc
DSS or Auxiliary Winding?
The DSS being directly connected to the drain node, its
power dissipation can sometimes affect the remaining heat
dissipation room of the MOSFET if the DSS power budget
is too high. Since the average voltage across the transformer
primary inductance is null at steady−state, the average
power taken by the DSS to supply the controller is: Vbulk x
ICC1, neglecting switching losses. If Vbulk is 370 V and
ICC1 roughly 1.0 mA, then the DSS power is already
370 mW. Suppose our package can dissipate 930 mW @
50°C TAMBIENT, then the room left for the MOSFET is only
930m–370m = 560 mW, naturally hampering the power
capability of the considered device. Also, the no−load
standby power cannot be lowered below these 370 mW at
high line since the DSS is always operating. A solution to
improve the situation could be to disable the DSS by an
auxiliary winding and reduce the power drawn by the
controller to almost nothing. This improves the no−load
standby power and the 100 mW barrier is in sight. Also, the
package power dissipation becomes entirely dedicated to the
MOSFET alone, considerably raising the power capability
of the considered device. So, when using an auxiliary
winding or the Dynamic Self−Supply?
• You need an extremely low standby power: use an
auxiliary winding
• You design a low power converter < 5.0 W: DSS is
okay
• EMI filtering is a sensitive issue, you need jittering:
use DSS
• You want to pass the maximum power from a
NCP101X member: use an auxiliary winding
• A precise short−circuit protection is a must: use DSS
• Safety motivates an open−loop protection: use an
auxiliary winding
Vcc
1
Rlimit
+
−
+
+
200 mV
CVcc
+
Aux.
Winding
R
+
VccOFF
i
Permanent
Latch
8
Gnd
+
−
+ i 7.4 mA?
Figure 6. An active clamp limits the voltage
excursion on the Vcc pin and triggers a latch if the
injected current is too high.
This protective feature can be used to protect the load and
the converter in case of broken optocoupler for instance.
Calculating the Rlimit resistor is easy as long as one
understands the particularity of a converter featuring an
extremely low standby power.
Self−supplying controllers in very low standby
applications often puzzles the designer. Actually, if a SMPS
operated at nominal load can deliver an auxiliary voltage of
an arbitrary 16 V (Vnom), this voltage can drop to below
10 V (Vstby) when entering standby. This is because the
recurrence of the switching pulses expands so much that the
low frequency re−fueling rate of the Vcc capacitor is not
enough to keep a proper auxiliary voltage. So care must be
taken when calculating Rlimit to 1) not trigger the Vcc over
current latch (by injecting 6.3 mA (minimum of the spec)
into the active clamp) in normal operation but 2) not to drop
too much voltage over Rlimit when entering standby.
Otherwise the DSS could be kept deactivated and the
standby performance would degrade. We are thus able to
bound Rlimit between two equations.
The Vcc Pin
The NCP101X features an active clamp on its Vcc pin:
when the voltage presents on this pin exceeds VccOFF +
200 mV typical, a zener−like circuitry starts to activate and
prevents the voltage from going further up. Of course, in
DSS mode, this circuit is unactive since the current source
stops the Vcc excursion at VccOFF. A circuit permanently
monitors the current flowing in this zener circuit. When this
current reaches a certain value (7.4 mA, typical), a
comparator permanently latches−off the controller and the
user must cycle the Vcc down to 3.0 V to reset the latch. As
a result, when you connect an auxiliary winding, you MUST
limit the current flowing into the Vcc pin otherwise a) you
have risks to destroy the active zener if the injected current
exceeds 15 mA b) you will latch your converter in off state
as soon as it starts−up.
Vnom 8.7 V Rlimit Vstby VccON (eq. 1)
Itrip
ICC1
Where:
Vnom is the auxiliary voltage at nominal load.
Vstdby is the auxiliary voltage when standby is entered.
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AND8134/D
converter time constants. The fine tuning of Rlimit thus
requires a few iterations and experiments on a breadboard to
check Vauxiliary variations. Once properly adjusted, the
fail−safe protection will preclude any lethal voltage
runaways in case a problem would occur in the feedback
loop. To fine tune Rlimit, please follow the steps:
1. Select the highest Rlimit value, e.g. 3.8 k given
by equation 1.
2. Remove the output load.
3. Connect a scope probe to the cathode of the
auxiliary diode while observing the output voltage
on another channel. Select one shot operation on
the scope, with a positive trigger monitoring Vaux.
4. Power the converter with the maximum input
voltage and short the optocoupler LED: Vaux
grows−up until the IC latches−off. Capture a
one−shot graph as on Figure 7, note Vout max and
Vaux max. Vout has gone, the controller is latched.
If not, reduce Rlimit and retry step 4 until it
latches−off. To quickly reset the controller, do a
brief short between Vcc and ground.
5. Stop the converter, and make sure Vout is back to
zero.
6. Now, as detailed in step 3, capture a fresh start−up
sequence and note Vaux max as in Figure 8.
7. If you have a sufficient margin between the
auxiliary level overshooting at start−up (16 V in
our case) and the level at which it latches−off
(32 V in the example), then you have a safe
design. If necessary, there is room to reduce Rlimit
and thus decrease the latching voltage.
8. Check the standby power and the voltage on pin 1
during no−load and maximum input voltage. If
Vpin1 is really close to 8.7 V in no−load conditions,
there are chances that the clamp activates and
increase the consumption. If you do not pass the
100 mW barrier, you can increase Rlimit to drop
Vpin1 slightly below 8.7 V (or check that the
watt−meter passes the barrier). Re−do step 1
through 7 to check the correct latch−off trigger.
Itrip is the current corresponding to the nominal operation.
It thus must be selected well below 6.3 mA to avoid false
tripping in overshoot conditions. We use the minimum value
of the spec to cover all distribution cases from NCP101X
lots to lots.
ICC1 is the controller consumption in skip mode. This
number slightly decreases compared to ICC1 from the spec
since the part in standby does almost not switch.
VccON is the level at which Vauxiliary must be maintained
to keep the DSS in the OFF mode. It is good to shoot above
8.0 V in order to offer an adequate design margin, for
instance 8.2 V. Also, we shall not trigger the active clamp too
much otherwise the consumption will increase and standby
power quickly degrades. When you try to pass the 100 mW
barrier, every single milliwatt counts!
Since Rlimit shall not bother the controller in standby, e.g.
keep Vauxiliary above 8.2 V (as selected above), we
purposely select a Vnom well above this value. As explained
before, experience shows that a 40% decrease can be seen on
auxiliary windings from nominal operation down to standby
mode. Let’s select a nominal auxiliary winding of 20 V to
offer sufficient margin regarding 8.2 V when in standby
(Rlimit also drops voltage in standby). In that case, the
current flowing through Rlimit will be ICC1 (the supply of
the controller) + Iclamp, Iclamp circulating in the activated
zener diode. If we select the NCP1013 operating at 65 kHz,
ICC1 = 1.0 mA. Selecting a clamp current Itrip of 5.0 mA
(to be below the 6.3 mA min. trip point) leads to a total
current of 6.0 mA. Applying equation 1 gives:
Rlimit 20 V 8.7 V 1.8 k Rlimit
6m
12 V 8.2 V 3.8 k
1m
If we design a 12 V power supply, then the ratio between
auxiliary and power must be: 12/20 = 0.6. The OVP latch
will activate when the clamp current exceeds 6.3 mA, at the
minimum of the spec. Theoretically predicting the auxiliary
drop from nominal to standby is an almost impossible
exercise since many parameters are involved, including the
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AND8134/D
Circuit Latches Here
22 V
Vout
Vaux
Figure 7. The circuit latches when Vaux grows−up to 32 V which corresponds
to Vout = 22 V.
Latching Level
Margin
Vaux
12 V
Vout
Figure 8. The selected resistor gives sufficient margin when Vout naturally
overshoots on start−up.
Please note that this protective option is more to protect
the converter and the load from a broken feedback loop
operation rather than precisely clamp the output voltage
with a precision of hundred of milli−volts.
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AND8134/D
Design Procedure with NCP101X, a Universal
Mains Design, with DSS
Due to application note “Evaluating the Power Capability
of NCP101X Members”, you have picked−up the right
device, corresponding to the power level you want to reach
with your supply. Suppose a NCP1013P06 has been selected
from Table 6, e.g. a 350 mA 65 kHz device and you plan to
build a 12 V−12 W adapter, operating at 50°C ambient,
featuring the DSS, operated on European mains (230 VAC
± 15%):
1. The rectified bulk voltage will be: VinDC min =
(230 – 15%) x 1.414 = 276 VDC, VinDC max =
(230 + 15%) x 1.414 = 374 VDC.
2. As detailed in the data sheet, it is not possible to
reflect a Flyback voltage greater than Vin, to avoid
forward biasing the MOSFET body−diode. Also,
care must be taken to not grow the drain voltage
above its breakdown value, 700 V. Therefore, the
turn−ratio will be bounded between two equations,
the first being the BVdss, the second one limiting
the reflected voltage to not forward bias the
MOSFET body diode:
that the valley of Vds(t) will not dip below ground
during off time ringing.
3. Taking a ratio of 20, will guide us to select the
right secondary diode. Its Peak Inverse Voltage
(PIV) is defined by: (VinDC max/N) + Vout
(eq. 4). This leads to a maximum reverse voltage
of (374/20) + 12 = 30.7 V, applied when the
primary MOSFET is on. A 40 V/3.0 A Schottky
diode will perfectly fit in our design, e.g. an
MBRA340.
4. As explained in the text, we will strive to keep the
converter in Discontinuous Conduction Mode
(DCM) with a duty−cycle less than 40% at VinDC
min to offer a comfortable DSS operation. If we
would not use the DSS, we could freely select the
duty−cycle of choice as long as we respect the
maximum value stated in the data−sheet. Keeping
the supply in DCM is of good practice since, in
that case, the turn−on losses are almost zero, if we
neglect the capacitive losses. We will need a few
equations to determine the primary inductance Lp
but the method will slightly differ from what we
are used to write. Here, several parameters are
bounding the design such as the available peak
current and the duty−cycle. Therefore, following
the below lines will let you know if the original
design parameters (power and voltage) are part
compatible and end−up with a working converter:
a) From the application note “Evaluating the
Power Capability of NCP101X Members” –
Table 3, we know that the available peak current is
actually the minimum of the specification, that is
to say Ip_selected = 320 mA (in our case, the peak
current is simply given by the minimum of the
data sheet, rounded to 320 mA).
N (Vout Vf) VinDC max Vleak 700 V
(eq. 2)
N (Vout Vf) VinDC min
(eq. 3)
With Vf, the secondary diode forward drop (0.5 V
for a Schottky in our case), Vleak the leakage
excursion (safely clamped by a RCD network) and
N, the turn ratio Np/Ns. If we take 80 V for the
leakage excursion (safety margin), then equation 2
gives a turn ratio of 20, whereas equation 3 gives
a turn−ratio of 22. We will chose a value of 20,
reflecting 20 x 12.5 = 250 VDC during the
MOSFET off time. This respects equation 2
(MOSFET BVdss not reached) and also ensures
b) Calculate the critical inductance not to exceed in order to stay DCM given the design parameters:
Lpcritical (VinDCmin · Vr)2 · 2 · Fsw · [Pout · (Vr2 2 · Vr · VinDCmin VinDCmin2)]
(eq. 4)
Lp critical 8.8 mH
c) Then evaluate the maximum value for the
primary inductance since we are bounded by the
duty−cycle max (maxDC = 40%) and the peak
current:
f) calculate the RCD clamping network, assuming
a leakage inductance of 2% of Lp: 2% (5.3 mH) =
106 H. Since we reflect 250 V, we will clamp at
300 V, limiting the drain excursion to 374 + 300 =
674 V 700 V BVdss. The peak current worse
case is now the maximum of the specification,
therefore 350 mA + 10% = 385 mA. We can now
apply the formulae for the RC element calculations:
Lpmax DCmax · VinDCmin · Tsw 5.3 mH
Ip_selected
(eq. 5)
d) check Lpmax Lp critical given by eq. 4. This
is okay.
e) check the maximum power you can get in DCM
with Lpmax and Ip_selected:
Pout 1 · Lpmax · Ip_selected2 · Fsw · 2
Rclamp 2 · Vclamp · (Vclamp−Vout · N)
Lleak · Ipmax2 · Fsw
= 29 k → 27 k, P = 3.0 W
(eq. 6)
→ Pout = 13.6 W, okay, greater than needed.
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(eq. 7)
AND8134/D
Cclamp model we made is available under both Intusoft’s IsSpice
and OrCAD’s PSpice. The Flyback template appears in
Figure 9, with our values plugged into the models. The
secondary network is a TL431 whose bandwidth has been
rolled−off via the 100 nF capacitor. Please note the presence
of the leakage inductance and the calculated RCD clamp. If
we missed the right values for this network, the library will
not blow, this is the nice thing with simulation.
Vclamp
(eq. 8) , with
Vripple · Fsw · Rclamp
Vripple = 20 V, Cclamp = 7.8 nF → 22 nF
The diode can be an MUR160, an ultra−fast diode.
Checking the Design with Spice
A Spice simulator offers a way to check our design
assumptions and see if they deliver the expected results. The
Iout
Xfmr
R3
200m RATIO = −0.05
4
26
D6
MBR340 Vint
+
L1
2.2H
5
33
R16
10m
37
+
Vout
38
Vout
Iprim
Lp
5.3mH
Rclp
27k
Clp
22nF
27
41
+
29
C1
470F
IC = 10
LLeak
106H
D3
MUR160
Iclamp
R4
100m
Isec
Iripple1
Vdrain
HV 5
6
2
IVcc
Vcc
C6
33F
IC = 8.4
Vout
Vint
4 FB
3
7
2
X1
NCP1013P06
1 Vcc Gnd 8
10
Vline
276
R15
1k
FB
3
R7
38k
12
C4
100nF
IC = 10
+
C3
1n
1
7
R5
10k
Figure 9. An IsSpice Simulation Template to Check the Design Validity
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39
C2
100F
IC = 10
IDrain
+
R17
300m
Rload
12
AND8134/D
13.5
8.80
12.5
8.40
2
Vout
1
Plot1
11.5
8.00
Vcc
10.5
7.60
9.5
7.20
(in volts)
Vout
(in volts)
Vcc
400 m
700
2.42 m
5.21 m
8.01 m
10.8 m
13.6 m
300 mA
Vds
Plot2
200 m
500
0
300
−200 m
100
Idrain
4
3
−400 m
−100
(in amperes)
Idrain
(in volts)
Vdrain
14.926 m
14.943 m
14.959 m
14.975 m
3
14.992 m
Figure 10. Results to Check Parameter Compliance
Conclusion
This application note describes the design methodology
of the NCP101X devices whose various features bring ease
and speed of design. By following the steps, it becomes
simple to develop and test with Spice, a power supply
tailored to your needs.
From Figure 10, we can see that low line confirms the
40% duty−cycle (Pout = 12 W) and the discontinuous
operation. Different waveforms would reveal a good safety
margin between Vds(t) and the 700 V BVdss.
ON Semiconductor and
are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice
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10
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