NCP1014STBUCGEVB Non-isolated Positive Output Buck AC/DC Converter Evaluation Board User's Manual http://onsemi.com EVAL BOARD USER’S MANUAL • Overload, Short−Circuit and Thermal Protected • Simple for Low Cost Mass Production • Universal Design for Wide Range of Output Currents and Voltages Figure 1. Evaluation Board Photo The monolithic power switcher, used in this application, greatly simplifies the total design and reduces time to production. The new line of the Power Switchers, NCP1010 through NCP1014, is ideal for this purpose. This IC in the SOT−223 package reduces size and is suitable for mass production. The design consists of input filter, rectifier with filtering capacitor, power stage with switcher and inductor, output ultrafast rectifier, output filtering capacitor, feedback loop with zener diode and optocoupler and indicating LED. The only component necessary for proper powering of the IC is the VCC capacitor. The IC is directly powered from the HV Drain circuit via internal voltage regulator. To eliminate the noise at the feedback input, some small ceramic capacitor with value of around 1.0 nF is necessary to be connected as close to the FB pin, as possible. This manual describes the way, how to easily design the simple, non isolated AC/DC converter for powering low voltage control part of mains applications with triac, or SCR power switch. Some examples are: dishwashers, microwave ovens, coffee machines, night illumination and so on. In comparison with resistive, or capacitive dropper is this solution more comfortable and features some advantages such as: • Wide Input Voltage Range 85 VAC – 265 VAC • Smaller Size, Lower Weight, Lower Total Cost • Good Line and Load Regulation, No Need of Additional Linear Regulators • Efficient Design with Up to 80% Efficiency SCHEMATIC DIAGRAM E2 220 mF/25 V C1 100 nF 2 D1 MUR160 E1 + 10 mF/400 V 1 R1 1k + 1 2 CON2 ARK750/2 L2 1 mH + D2 1N4007 VCC HV GND FB L1 1.5 mH CON2 ARK500/2 LD1 GRN IO2 NCP1014ST IO1 PC817 E3 47 mF/25 V ZD1 11 V C2 1 nF Figure 2. Complete Schematic Diagram of the 12 V/0.2 A Converter © Semiconductor Components Industries, LLC, 2012 October, 2012 − Rev. 2 1 Publication Order Number: EVBUM2143/D NCP1014STBUCGEVB SELECTION OF CRITICAL COMPONENTS Inductor selection The average current through the inductor over one switching cycle can be expressed by Equation 4. For the selected output power need to be selected certain minimum value of the inductance. This value is dependent on the mode of operation. Reduced value results in Discontinuous Conduction Mode of operation (DCM). Practically was found, that the borderline between Continuous Conduction Mode of operation (CCM) and DCM is commonly set slightly below maximum output power. The result is low cost of the inductor, freewheeling diode (trr > 35 ns), higher efficiency and lower cost. The negative result is in lower output power and higher cost of the NCP101x Power Switcher. The current ripple in the inductor during the Ton time may be expressed by Equation 1. DIripple(Ton) + Ton @ Vds * VO) ǒ(V min *L min Ǔ Ic + fop_min @ ǒLVO Ǔ L min + Ǔ @ Ton ) ǒ2DI)ripple Ǔ @ ToffǓ Iinit (eq. 4) (2 @ VO @ IO @ (V min * Vds * VO)) (eq. 5) (DIripple 2 @ fop_min @ (V min * Vds)) IO = Output DC Current. The theoretical maximum output power will be shown in Equation 6. (eq. 1) Pout_max + L min @ (Iset 2 * Iinit 2) @ fop_min @ (V min *Vds) ǒ(V min Ǔ *Vds*VO) (eq. 6) 2 The current ripple in the inductor during the normal operation will be shown in Equation 7. DIripple + ((V min * Vds * VO) @ VO) (eq. 7) ((V min * Vds) @ fop_min @ L min) The output current will be shown in Equation 8. IO + fop_min @ (eq. 2) min DIripple 2 ) Iinit Ic = Inductor Operating Current, fop_min = Minimum Operating Frequency The theoretical minimum inductor value corresponds to Equation 5. Where: Ton = ON Time, Internal Power Switch in ON, Vmin = Minimum Rectified Input Voltage, Vds = Drain−to−Source Voltage Drop, Vo = Output Voltage, Lmin = Minimum Inductor Value. The current ripple in the inductor during the Toff time may be expressed by Equation 2. DIripple(Toff) + Toff @ ǒǒ ((Iset ) Iinit) @ Ton ) (Iset ) Iinit) @ Toff) (eq. 8) 2 Toff = OFF Time, Internal Power Switch in OFF. The current through the inductor at the beginning of the Ton time is shown by Equation 3. Iinit + Iset * DIripple (eq. 3) Iset = Peak Switching Current Set by the FB Loop. Table 1. TABLE OF PRESELECTED INDUCTORS (Vmin = 120 V, Vds = 9 V, VO = 12 V, Iset = 0.405 A, fop_min = 59 kHz) NOTE: Inductance (mH) Coilcraft Part Number (see appendix for address) DIripple (A) Output Current (A) 470 RFB0810−471 0.39 0.25 680 RFB0810−681 0.27 0.32 820 RFB0810−821 0.22 0.34 1000 RFB0810−102 0.18 0.36 1500 RFB0810−152 0.12 0.40 The output current is the theoretical value and need to be multiplied by the efficiency (~0.7). http://onsemi.com 2 NCP1014STBUCGEVB Freewheeling diode selection The freewheeling diode needs to be selected accordingly to the mode of operation. For the CCM operation needs to be used the ultra fast diode with trr < 35 ns. For the DCM operation the standard ultra fast diode with trr < 75 ns is enough. Table 2. TABLE OF PRESELECTED FREEWHEELING DIODES Part number VRRM (V) IF(AV) (A) trr (ns) Package MUR160 600 1.0 75 Axial Lead MURA160T3 600 1.0 75 SMD SMA MURS160T3 600 1.0 75 SMD SMB MURS260T3 600 2.0 75 SMD SMB Electrical Specification of the example at Figure 2: Input: 85 VAC – 265 VAC Output: + 12 V / 200 mA NOTE: The polarity is proportional to common line. COMPONENT LAYOUT Figure 3. Component Layout – Top Side Figure 4. Component Layout – Bottom Side PCB LAYOUT Figure 5. PCB Layout http://onsemi.com 3 NCP1014STBUCGEVB EMI TEST RESULTS Test Conditions: Input: 230 VAC Output: 11.7 VDC Load: Resistive 68 R Figure 6. Conducted EMI TEST PROCEDURE • 1 DC Volt-Meter able to measure up to 20 V DC (e.g. Necessary Equipment: • 1 Current limited 90 − 265 Vrms AC source (current DC ELECTRONIC LOAD + − • • 1 DC Amp-Meter able to measure up to 500 mA DC • (e.g. KEITHLEY 2000) 1 DC Electronic Load (e.g. AGILENT 6060B) V V A A REGULATED AC SUPPLY • KEITHLEY 2000) limited to avoid board destruction in case of a defective part) or a 380 VDC source (e.g. AGILENT 681x) 1 AC Volt-Meter able to measure up to 300 V AC (e.g. KEITHLEY 2000) 1 AC Amp-Meter able to measure up to 1 A AC (e.g. KEITHLEY 2000) Figure 7. Test Setup • Power down the load • Power down Uin • End of test Test Procedure • • • • • • Connect the test setup as shown in Figure 7. Apply an input voltage, Uin = 90 − 265 Vac Apply Iout(load) = 0 A Check that Uout is 12 Vdc Increase Iout(load) load to: 12 V / 200 mA Check that Uout is 12 V NOTE: Be careful when manipulating the boards in operation, lethal voltages up to 265 Vac are present on the primary side. http://onsemi.com 4 NCP1014STBUCGEVB BILL OF MATERIAL Table 3. NCP1014STBUCGEVB EVALUATION BOARD BILL OF MATERIALS Designator QTY Description Value Tolerance C1 1 Capacitor X2 100 nF C2 1 CMS Capacitor CON1 1 CON2 Substitution Allowed RoHS Compliant Footprint Manufacturer Manufacturer Part Number ±10% Through Hole Vishay F1772−410−2030 Yes Yes 1 nF ±10% 1206 AVX 12065C102KAT2A Yes Yes Input Terminal Block LP7.5/2/903.2 OR − LP7.5/2 WeidMuller LP7.5/2/903.2 OR Yes Yes 1 Output Terminal Block PM5.08/2/90 − PM5.08/2 WeidMuller PM5.08/2/90 Yes Yes D1 1 Ultrafast Power Rectifier MURA160 − SMA ON Semiconductor MURA160T3G No Yes D2 1 1 A, 1000 V Standard Rectifier 1N4007 − Axial Lead ON Semiconductor 1N4007RLG No Yes E1 1 Electrolytic Capacitor 10 uF / 400 V ±20% Through Hole Panasonic ECA2GHG100 Yes Yes E2 1 Electrolytic Capacitor 220 uF / 25 V ±20% Through Hole Panasonic ECA1EHG221 Yes Yes E3 1 Electrolytic Capacitor 47 uF / 25 V ±20% Through Hole Rubycon 25ML47M6.3X5 Yes Yes IO1 1 Opto−Coupler PC817 − DIL−4 Sharp PC817X1J000F Yes Yes IO2 1 Monolithic Power Switcher NCP1014 − SOT−223 ON Semiconductor NCP1014ST65T3G No Yes L1 1 Inductor 1.5 mH ±10% RFB0810 Coil Craft RFB0810−152 Yes Yes L2 1 Inductor 1 mH / 1.6 A ±10% Through Hole Fastron SMCC−R10X−YY Yes Yes LD1 1 LED Green LED 5 mm − Through Hole Avago HLMP−HM57−SV000 Yes Yes R1 1 CMS Resistor 1 kW ±1% 1206 Vishay RCA12061K00FKEA Yes Yes ZD1 1 Zener Diode 11 V ±5% SOD−123 ON Semiconductor MMSZ11T1G No Yes ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). 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