DN05073/D Design Note – DN05073/D Universal AC Input, 5.3V2A Output, 10.6 Watt Charger Device Application Input Voltage Output Power Topology I/O Isolation NCP1360BBCC NCP1360BCCC Mobile, tablet Charger, adapter 90 to 264 Vac 10.6W Quasi Resonant Flyback Yes Item Rated Input Voltage Input Voltage Range Input Frequency Range Inrush Current Average Efficiency Average Eff. At cable end Standby Power Output Voltage Output Current Rated Output Power Ripple and Noise Rise Time Startup Time Over Shoot Transient Response Output Specification 100Vac~240Vac 90Vac~264Vac 47Hz~63Hz <30A >82% >78% <50mW&75mW 5V~5.5V, 5.3V at 2A 2A >10.6W <120mV <30ms <1.5s <6.4V 4.5V~5.5V Circuit Description This design note describes a 10.6 watt, universal AC input, isolated Quasi-Resonant flyback converter for smart phone, tablet charger and smart socket power supply etc. The featured power supply is a primary side constant voltage and current regulation utilizing ON semiconductor’s new NCP1360 current mode controller which is in TSOP-6 package. This Design Note provides the complete circuit schematic details, layout, test data and BOM for 5.3 volts, 2 amps power supply. Test Condition 264Vac and 2A load Measured at board end Measured at cable end 90Vac~264Vac 90Vac~264Vac and 0~2A 90Vac~264Vac 90Vac~264Vac 90Vac~264Vac, 1uF+0.1uF CAP@E-load At No/Full load,115Vac&230Vac 90Vac~264Vac and 0~2A At 1m USB cable end 0.1A-1.9A, 0.25A/us,10ms cycle D1, C1, C1, L1, NTC is 2.5ohm negative temperature coefficient resistor to provide inrush protection, FR1 provides short-circuit protection when large AC input current occurs. 2. NCP1360 control circuit R8 and R9 consists of voltage simple network to set output voltage, C12 is a delayed capacitor to delay switching on to valley. Both NCP1360BBCC and NCP1360BCCC are all tested in this design, it has almost same performance except standby power and dynamic response. R12 and R13 is a current sensing resistor to decide how much current can be set, R10 and CS pin parasitic capacitor consists of a filter to filter current spike. R19, C11 and C9 consist of a type II compensation network to provide voltage feedback control loop compensation. 1. Input circuit Rectifier, filter and EMC circuit formed by R5 and R11 is startup resistor, two 7.5Mohm are used in series to reduce power loss, R4, April 2015, Rev. 0 www.onsemi.com 1 DN05073/D D6 and C4 consist of Vcc supply circuit, R4 can adjust Vcc voltage and also prevent D6 from an inrush current. An RCD-R clamp consisting of D5, R3, R6, and C7 limits drain voltage spikes caused by leakage inductance, resistor R6 has a relatively large value to prevent any excessive ringing on the drain voltage waveform and R3 can limit the reverse recovery current through D5. Size: 47mmx34mmx15mm 3. Output rectification and filter The transformer (T1) secondary is rectified by D2, a Schottky barrier-type diode (chosen for higher efficiency), and filtered by C3, C5 and C8. In this application, C3 and C5 have Sufficiently low ESR characteristics to allow meeting the output voltage ripple requirement Without adding an LC post filter. C6 and R7 are snubber network of D2 to eliminate excessive ringing on secondary voltage waveform. R14 is a dummy load to prevent output voltage rising at no load. Key Features Primary Side Regulation(PSR) CC/CV control Quasi-Resonant current mode control with Valley Switching Valley lockout avoids audible noise at valley jumping operation Built in 4ms soft start 110kHz maximum clamp frequency operation Adjustable voltage control loop compensation 300mV cable drop compensation Wide Operation VCC range (up to 30 V) Cycle by cycle current limit Support external 1500uF capacitive load startup Built in Vcc OVP_(typical 26v) Built in output UVP in CC mode_(3V+/6.7%) Output OCP, SCP, OVP and controller OTP function CS pin open and short protection Vs pin open and short protection Meet COC V5 Tier 2 100pF Y capacitor Travel Adapter” (TA) form factor April 2015, Rev. 0 www.onsemi.com 2 DN05073/D Circuit Schematic PCB layout Demoboard Photo April 2015, Rev. 0 www.onsemi.com 3 DN05073/D Standby Power for NCP1360BBCC at No Load 40 37.5 35 32.5 30 27.5 Pin(mW) 25 22.5 20 17.5 15 12.5 10 7.5 5 2.5 0 90 115 132 180 230 264 180 230 264 Vac(V) Standby Power for NCP1360BCCC at No Load 70 65 60 55 50 Pin(mW) 45 40 35 30 25 20 15 10 5 0 90 115 132 Vac April 2015, Rev. 0 www.onsemi.com 4 DN05073/D Average Efficiency Between 25%, 50%, 75% And 100% Load 85 84.5 84 Efficiency(%) 83.5 83 82.5 82 81.5 81 80.5 80 90 115 132 180 230 264 Vac(V) Efficiency Vs Load Curves 86 84 Efficiency(%) 82 80 115Vac 78 230Vac 90Vac 76 264Vac 74 72 70 0.1 0.2 0.5 1 1.5 2 Io(A) April 2015, Rev. 0 www.onsemi.com 5 DN05073/D I-V Curves 6 5.5 5 4.5 4 Vo(V) 3.5 115Vac 3 230Vac 2.5 90Vac 264Vac 2 1.5 1 0.5 0 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 Io(A) April 2015, Rev. 0 www.onsemi.com 6 DN05073/D Output Ripple Voltage (Test condition: tested at E-load with 1m cable, 1uF E-CAP and 0.1uF ceramic in parallel) 90Vac and 2A load 115Vac and 2A load 230Vac and 0.5A load 264Vac and 0.5A load Transient Response for NCP1360BBCC Test Condition: 0.2A-1.8A, 250mA/us 10ms cycle, 115Vac April 2015, Rev. 0 Test Condition: 0.1A-1.9A, 250mA/us 10ms cycle, 115Vac www.onsemi.com 7 DN05073/D Transient Response for NCP1360BCCC Test Condition: 50mA-2A, 250mA/us 20ms cycle, 115Vac Test Condition: 50mA-2A, 250mA/us 10ms cycle, 115Vac Test Condition: 0.2A-1.8A, 250mA/us 10ms cycle, 115Vac Test Condition: 0.1A-1.9A, 250mA/us 10ms cycle, 115Vac OVP SCP Test condition: 264Vac, no dummy load April 2015, Rev. 0 Test condition: SC at board end www.onsemi.com 8 DN05073/D Startup Time 90Vac and 2A CC load 230Vac and 2A CC load Output Voltage Rise Time 115Vac and 2A CC load 230Vac and 2A CC load Output Voltage Overshoot 115Vac and no load April 2015, Rev. 0 115Vac and 2A CC load www.onsemi.com 9 DN05073/D External 1500uF capacitive load startup Test condition: Ext. 1500uF capacitor, 2A CC load with 1V Von voltage set, 90Vac MOSFET Drain Voltage Startup at 264Vac and 2A CC load Inrush Current Working at 264Vac and 2A CC load Secondary Diode Reverse Voltage 264Vac and 2A CC load April 2015, Rev. 0 264Vac and 2A CC load www.onsemi.com 10 DN05073/D BOM Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Qty Referen Type 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 C8 C6 C9 C10 C12 C4 C11 C7 D1 D2 D5 D4 D6 T1 FR1 U1 Q1 NTC L1 R8 R10 R9 R4 R15 R19 R2 R12 R13 R3 R7 R6 R14 R18 R5 R11 C1-2 C3 C5 April 2015, Rev. 0 Part Name MFR Value Ceramic Std std 0.1uF,50V Ceramic Std std 1000pF,50V Ceramic Std std 100pF,50V Ceramic Capcitor CS65-B2GA101KYNKA TDK 100pF,Y1 Ceramic Std std 10pF,50V Ceramic C2012X7R1E105K TDK 1uF,35V Ceramic Std std 33nF,50V Ceramic Capcitor C3216C0G2J391J TDK 390pF,630V Bridge rectifier LMB6S FSC/Others 1A,600V 20A,45V Schotty rectifier MBR2045MFS/FERD30S ON/ST Standard rectifier DFLR1600 Diodes 1A,600V ON 0.2A,200V Switching diode BAS20HT1G Transformer EI16/12/8 Customized transformer Micro Fuse 20T-016H HollyFUSE 1.6A,250Vac PSR Controller NCP1360BBCC/BCCC ON NMOSFET SW6N70 SAMWIN 6A, 700V NTC SPNL07D2R5MBI Sunlord 2.5ohm fixed inductor 7447462221 Wurth 220uH Resistor Std Std 100K Resistor Std Std 1K Resistor Std Std 30.9k Resistor Std Std 4.7 Resistor Std Std 47 Resistor Std Std 82k Resistor Std Std NA Resistor Std Std 1.6 Resistor Std Std 1.8 Resistor Std Std 150 Resistor Std Std 20 Resistor Std Std 330k 1.6k@600Hz, Resistor Std Std Resistor Std Std 1M Resistor Std Std 7.5M Electrolytic capaci AX/KSH106M400T1Z5H Rubycon/TEAP 10uF,400V Electrolytic solid PCH477M6R3S1AGE08K TEAPO 470uF,6.3V www.onsemi.com Package Description 603 Capacitor, Ceramic, 10% 603 Capacitor, Ceramic, 10% 603 Capacitor, Ceramic, Chip, 10% Lead type HV Ceramic Capacitor,safety sta 603 Capacitor, Ceramic, Chip, 10% 805 Capacitor, Ceramic, Chip, 10% 603 Capacitor, Ceramic, Chip, 10% 1206 Capacitor, Ceramic, Chip, 5% Micro-DIP Bridge Rectifier, 600V, 1A SO8FL Schotty Rectifier, 20A, 45V/30A POWERDI123 Standard Rectifier, 1A, 600V SOD323 Switching diode, SMD TH type Core: EI16/12/8, customized bob Radial lead Micro fuse, 1.6A/250Vac, Radial TSOP-6 PSR Controller without HV start IPAK NMOS, 6A, 700V, IPAK lead type NTC, 2.5ohm, 3A Lead type Axial leaded fixed inductor 805 Resistor, Chip, 1/5W, 1% 603 Resistor, Chip, 1/8W, 1% 603 Resistor, Chip, 1/8W, 1% 603 Resistor, Chip, 1/8W, 1% 603 Resistor, Chip, 1/8W, 1% 603 Resistor, Chip, 1/8W, 1% 603 Resistor, Chip, 1/8W, 1%, 805 Resistor, Chip, 1/5W, 1% 805 Resistor, Chip, 1/5W, 1% 1206 Resistor, Chip, 1/4W, 1% 805 Resistor, Chip, 1/5W, 1% 1206 Resistor, Chip, 1/4W, 1% 8603 Resistor, Chip, 1/8W, 1% 603 Resistor, Chip, 1/8W, 1% 1206 Resistor, Chip, 1/4W, 1% 10mm(die.)x12size,10mmx12.5mm 6.3mm(die.)x8Aluminum Solid Capacitor, size, 11 DN05073/D References ON Semiconductor datasheet for NCP1360/5 CC/CV primary side PWM current mode controller. Disclaimer: ON Semiconductor is providing this design note “AS IS” and does not assume any liability arising from its use; nor does ON Semiconductor convey any license to its or any third party’s intellectual property rights. This document is provided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associated with its use, including, but not limited to, compliance with all regulatory standards. ON Semiconductor may change any of its products at any time, without notice. Design note created by David Dou; e-mail: [email protected] April 2015, Rev. 0 www.onsemi.com 12