TND318/D Rev. 1, Jul-06 60 W Adapter Documentation Package Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 1 TND318/D © 2006 ON Semiconductor. Disclaimer: ON Semiconductor is providing this reference design documentation package “AS IS” and the recipient assumes all risk associated with the use and/or commercialization of this design package. No licenses to ON Semiconductor’s or any third party’s Intellectual Property is conveyed by the transfer of this documentation. This reference design documentation package is provided only to assist the customers in evaluation and feasibility assessment of the reference design. It is expected that users may make further refinements to meet specific performance goals. Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 2 TND318/D 1 Overview This reference document describes a built-and-tested, GreenPointTM solution for a 60 W power adapter. The reference design circuit consists of one single-sided 100 mm x 52 mm printed circuit board. Height is 25 mm. 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. Figure 1 Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 3 TND318/D 2 Introduction 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 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%). Many regulations have been proposed around the word. Hereafter is the list of some of the most important ones: • Energy Star: applicable in the US and international partners o Energy Efficiency Criteria for active mode Nameplate Output Power (Pno) 0 to < 1 Watt >1 and ≤49 Watts > 49 Watts Minimum Average Efficiency in Active Mode (expressed as decimal) ≥ 0.49 * Pno ≥ (0.09 * Ln(Pno)) + 0.49 ≥ 0.84 o Energy Consumption Criteria for No Load Nameplate Output Power (Pno) 0 to <10 Watts ≥10 to ≤ 250 Watts Maximum Energy Consumption in NoLoad Mode ≤ 0.5 Watt ≤ 0.75 Watt Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 4 TND318/D • California Energy Commission: o Effective January 1, 2007 Nameplate Output 0 to < 1 Watt >1 and ≤ 49 Watts > 49 Watts Minimum Efficiency in Active Mode 0.49 * Nameplate Output 0.09 * Ln(Nameplate Output) + 0.49 0.84 Maximum Energy Consumption in No-Load Mode 0 to <10 Watts 0.5 Watt ≥10 to ≤ 250 Watts 0.75 Watt Where Ln (Nameplate Output) = Natural Logarithm of the nameplate output expressed in Watts o Effective July 1, 2008 Nameplate Output 0 to < 1 Watt >1 and ≤ 51 Watts > 51 Watts Minimum Efficiency in Active Mode 0.5 * Nameplate Output 0.09 * Ln(Nameplate Output) + 0.5 0.85 Maximum Energy Consumption in No-Load Mode Any output 0.5 Watt Where Ln (Nameplate Output) = Natural Logarithm of the nameplate output expressed in Watts • European Union Code of Conduct o No-load Power Consumption Rated Output Power > 0.3 W and < 15 W > 15 W and < 50 W > 50 W and < 60 W > 60 W and < 150 W No-load power consumption Phase 1 Phase 2 1.1.2005 1.1.2007 0.30 W 0.30 W 0.50 W 0.30 W 0.75 W 0.30 W 1.00 W 0.50 W Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 5 TND318/D o Energy-Efficiency Criteria for Active Mode for Phase 1 (for the period 1.1. 2005 to 31.12 2006) Rated Output Power 0 < W < 1.5 1.5 < W < 2.5 2.5 < W < 4.5 4.5 < W < 6.0 6.0 < W < 10.0 10.0 < W < 25.0 25.0 <W< 150.0 Minimum Four Point Average (see Annex) or 100 % Load Efficiency in Active Mode 30 40 50 60 70 75 80 Energy-Efficiency Criteria for Active Mode for Phase 2 (valid after 1.1.2007) Nameplate Output Power (Pno) Minimum Four Point Average (see Annex) or 100 % Load Efficiency in Active Mode (expressed as a decimal)2 0<W<1 ≥ 0.49 * Pno 1 < W < 49 ≥ (0.09 * Ln(Pno)) + 0.49 49 < W < 150 ≥ 0.843 o Notes 2 “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. 3 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%). • Korea: o External Power Supply - No load: 0.8 W o Battery Charger - No load: 0.8 W 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. Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 6 TND318/D 3 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. 4 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 negatively impacted, due to the increase in the complexity of the design. 5 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. 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. Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 7 TND318/D 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 • Overvoltage Protection • Brown-Out Protection • Two Externally Triggerable Fault Comparators (one for 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) 6 Specifications Parameter Input Voltage range Frequency range Brown out threshold Brown out hysteresis Input inrush current No-load input power Output Output voltage Voltage total regulation Load output current Start-up overshoot Transient regulation Transient recovery time Ripple Over current protection Over voltage protection Total Output Power Continuous Output Power Conducted EMI Margin Efficiency Operation Temprature Test Conditions Min Typ 90 47 65 Max Unit 265 63 75 65 0.3 Vac Hz Vac Vac A W ±2 5 10 300 200 100 7 14.5 V % A % mV us mV A V 10 Cold start 230 Vac Input 240 Vac 12 90 Vac to 265 Vac input and 0 to 5 A output 90 Vac to 265 Vac 90 Vac to 265 Vac 2.5 A to 5 A Step 2.5 A to 5 A Step; Recovery to 1% 20 MHz Bandwidth, Full Load 90 Vac to 265 Vac Open Voltage Feedback Loop Total power EN55022 class B Input 230 Vac, Full Load Full Load, Free Air Convection cooling Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 8 0 5.5 13.5 14 60 6 88 0 40 W dB % °C TND318/D 7 Reference Design Performance No-load consumption Low load 0.5 W consumption N o - Lo ad Inp ut Po wer ( B y Y OKOGA W A W T 2 10 ) Lo w- Lo ad Inp ut Po w er ( B y Y OKOGA W A W T 2 10 ) 300 1000 250 950 900 200 850 150 800 100 750 700 50 50 100 150 200 250 50 300 100 150 200 250 300 I n p u t Vo l t a g e ( Va c ) I nput Vol t a ge ( Va c ) Output voltage 12.25 V; output current 0 A Output voltage 12.25 V; output current 42 mA Efficiency E f f i c i e nc y 90. 00 89. 00 88. 00 87. 00 86. 00 85. 00 84. 00 83. 00 82. 00 81. 00 Ef f ci e i ncy 80. 00 85 105 125 145 165 185 205 225 245 265 I nput ( V A C ) Efficiency vs input voltage at full load Efficiency Effi ciency 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 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 60 LOAD(Watt) Efficiency vs Load at 110 Vac input Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 9 Efficiency 0 5 10 15 20 25 30 35 40 45 50 55 60 LOAD(Watt) Efficiency vs Load at 220 Vac input TND318/D Voltage Waveform of MOSFET Q2 Drain @ full load 90 Vac input; Switching frequency 31 kHz 250 Vac input; switching frequency 92 kHz Drive Waveform of MOSFET Q1 (Synchronous Rectifier) @ full load 90 Vac input; CH1 Vgs; CH2 Vds 250 Vac input; CH1 Vgs; CH2 Vds VDS of Q2 and Vcc Waveform @ Over load 90 Vac input; Over load at 5.5 A; CH1 Vds; CH2 Vcc Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 10 250 Vac input; Over load at 5.9 A; CH1 Vds; CH2 Vcc TND318/D Dynamic Load transient response @ Step load 2.5 A to 5 A to 2.5 A Input voltage 90 Vac Input voltage 250 Vac Over Voltage Protection (Voltage feedback open circuit mode) @ full load CH1: BO pin; CH2:Output (OVP 13.91 V) EMI @ full load 110 Vac input Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 11 220 Vac input TND318/D 8 Board Pictures Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 12 TND318/D 9 Schematic F1 T3A250VAC R3 C6 MOV471 0.22uF/X2 C7 C8 150uF400V 10nF1kV C1 2.2nF/Y1 C5 4.7nF1kV C2 C3 2200uF16V 2200uF16V L1 1.8uH5A LINE 90VAC-264VAC L3 150uH L4 20mH + R2 1M D1 GBU608 1 D2 MBR160 R4 47k/1W 2 - R6 1M NTRL D3 1N4937 D4 MMSD4148 R26 5.1k R28 9.1k 2 1 C14 0.1uF50V FB DRV U3 NCP1337 BO R15 2k C12 47uF25V D6 MMSZ15 CS 5 3 T2 CT1:100 Q1 NTP75N06 3 C10 1nF50V 8 HV 6 U1B PC817C VCC U2B PC817C R18 2k GND R19 1M R14 1k C11 0.1uF50V 4 R13 15k RTN 7,8,9 34T, 0.5mm LP=600uH; Q2 MMBT3904L 12V5A R5 4.7ohm R1 5ohm NTC R10 1M C4 470uF16V C9 2.2nF100V 3T,TIW0.5mmx6 12V L2 75uH 10,11,12 R23 10ohm R16 1k 4 Q3 9A650V 3T, 0.5mm R21 27ohm R11 10ohm D7 MMSD4148 Q5 MMBT3904L 5 T1 PQ3220 R27 2.4k C15 100pF50V R29 10k R30 0.18/1W D8 MMSD4148 R22 5.1k R7 2k R8 5.1k U1A PC817C R9 10k R12 1k R17 20k D5 MMSZ13 C13 0.1uF50V R20 10k R24 1k Q4 MMBT3906L Q6 MMBT3904L R25 1k Q7 MMBT3906L U2A PC817C Q8 MMBT3904L U4 TL431A R31 5.1k R32 10k 10 Board Layout Assembly Drawing Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 13 TND318/D C16 0.1uF50V Global layer Top layer Bottom layer Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 14 TND318/D 11 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 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Quantity 1 2 1 1 1 1 1 1 1 4 1 1 1 1 1 3 1 1 1 1 1 1 1 1 4 1 2 1 4 1 1 1 3 4 4 2 5 1 1 1 1 1 1 1 1 2 1 1 1 Reference C1 C2, C3 C4 C5 C6 C7 C8 C9 C10 C11, C13, C14, C16 C12 C15 D1 D2 D3 D4, D7, D8 D5 D6 F1 L1 L2 L3 L4 Q1 Q2, Q5, Q6, Q8 Q3 Q4, Q7 R1 R2, R6, R10, R19 R3 R4 R5 R7, R15, R18 R8, R22, R26, R31 R9, R20, R29, R32 R23, R11 R12, R14, R16, R24, R25 R13 R17 R21 R27 R28 R30 T1 T2 U1, U2 U3 U4 PCB Part 2.2 nF/Y1 2200 uF, 16 V 470 uF, 16 V 4.7 nF, 1 kV 0.22 uF/X2 150 uF, 400 V 10 nF, 1 kV 2.2 nF, 100 V 1 nF, 50 V 0.1 uF, 50 V 47 uF, 25 V 100 pF, 50 V GBU608 MBR160 1N4937 MMSD4148 MMSZ13 MMSZ15 T3A250VAC 1.8 uH, 5 A 75 uH 150 uH 20 m H NTP75N06 MMBT3904L 9 A, 650 V MMBT3906L 5 ohm NTC 1M MOV471 47 k/1 W 4.7 ohm 2k 5.1k 10k 10 ohm 1k 15k 20k 27 ohm 2.4k 9.1k 0.18/1 W PQ3220 CT1:100 Toroid or UU9.8 PC817C NCP1337 TL431A PCB5.2*10 Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 15 Manufacturer ON Sem iconductor ON Sem iconductor ON Sem iconductor ON Sem iconductor ON Sem iconductor ON Sem iconductor ON Sem iconductor ON Sem iconductor ON Sem iconductor ON Sem iconductor TND318/D 12 Appendix 12.1 Product Information • NCP1337 Quasi Resonant Controller featuring Over 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 12.2 References CECP (China): • http://www.cecp.org.cn/englishhtml/index.asp Energy Saving (Korea) • http://weng.kemco.or.kr/efficiency/english/main.html# Top Runner (Japan): • http://www.eccj.or.jp/top_runner/index.html EU Eco-label (Europe): • http://europa.eu.int/comm/environment/ecolabel/index_en.htm • http://europa.eu.int/comm/environment/ecolabel/product/pg_portablecomputers_en.htm EU Code of Conduct (Europe): • http://energyefficiency.jrc.cec.eu.int/html/standby_initiative.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_supplies.power_supplies_consumers 1 Watt Executive Order: • http://oahu.lbl.gov/ • http://oahu.lbl.gov/level_summary.html Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 16 TND318/D 12.3 Transformer Specification Lp(W1+W4)=600uH+/-7%@10KHz 1V Leaking induction: 60uH max CORE: PQ32-20 Pin10,11,12 Pin1 W2,W5 W4 Secondary Side Pin7,8,9 Pin2 W1 Primary Side Pin3 Pin4 W3 Pin5 T1 PQ3220 Semiconductor Components Industries, LLC, 2006 July, 2006 – Rev 1 17 TND318/D ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). 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