NCP1076/7: Universal Input, 5 V or 12 V Output, up to 24 W Power Supply

DN05049/D
Design Note – DN05049/D
Universal AC Input, 5 or 12 Volt
Output, 15 to 24 Watt Power Supply
Device
Application
Input Voltage
Output Power
Topology
I/O Isolation
NCP1076/77
NCP431
Smart Meters,
Electric Meters,
White Goods
85 to 270 Vac
15 to 25 W
CCM Flyback
Isolated
( 3 kV)
Output Specification
Output Voltage
Ripple
Nominal Current
Max Current
Min Current
5 Vdc or 12 Vdc
200 mV p/p @ full load
4A/1.75A Amps (5V/12V)
4.5/2.0 Amps
zero
PFC (Yes/No)
Average Efficiency
Inrush Limiting / Fuse
Operating Temp. Range
Cooling Method /
Supply Orientation
Signal Level Control
No (Pout < 25W)
80% minimum typical at 50% load
Inrush resistor (Optional - R1) & Fuse
0 to +50°C
Convection
None
Circuit Description
This design note describes a simple, low power
(25W or less), universal AC input, constant
voltage power supply intended for powering
utility electric meters or similar industrial
equipment or white goods where isolation from
the AC mains is required and low cost and high
efficiency is essential.
programmable zener plus optocoupler feedback
scheme provides for excellent line and load
regulation along with high input-to-output
isolation.
Performance characteristics for efficiency,
output ripple, internal MOSFET drain switching
characteristics, and conducted EMI are shown
in the figures and plots below.
.
The featured power supply is a simple CCM
flyback topology utilizing ON Semiconductor’s
new NCP1076/1077 series of monolithic
switchers in an SOT-223 package. This Design
Note provides the complete circuit schematic
details and transformer design for 5V/4A and
12V/1.75A power supplies. Other output
voltages from 3.3 Vdc up to 28 Vdc are easy to
implement by modifying the values (or ratings)
of a few of the secondary side output
components and the flyback transformer’s
secondary winding (T1). The simple input EMI
filter is adequate to pass Level B for FCC
conducted EMI compliance and the NCP431
August 2013, Rev. 0
Key Features
 Universal AC input range (85 – 270 Vac).
 Input filter (pi-network) for conducted EMI
attenuation and input transient protection.
 Very low standby (no load) power consumption.
 Frequency foldback under light load and/or
overcurrent conditions.
 Secondary circuit easily configured for different
output voltage/current combinations.
 Inherent over-current, over-voltage and over
temperature protection.
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1
DN05049/D
12V Circuit Schematic
1
R12
5.6K
J1
L1A
F1
1.5A
C1
AC Input
T1
1 mH
0.1uF
"X"
R1
4.7 ohms
3W
R2A
C2
0.1uF
"X"
L1B
3.3M
D1-D4
MRA4007
X4
C3
1 mH
5.6K
6
68K
1/2W
1nF
1kV
8
D5
22uF
400V
U1
R2B
3.3M
R13
R3
C4
4
Primary
Ground
Plane
1N4937
10
R11
C13
47
1nF
D7
3
2
1
NCP1077
(65 kHz)
C5
22uF
25V
J2
C9A C9B
+
5
R4
2.7K
C7
1nF
MMSD
103
R5
D6
C6
4.7uF
50V
10
C10
MBRS
3100
1
7
Secondary
Ground
Plane
9
12Vout
_
1000uF, 16V
C8
1nF "Y1"
NOTES:
R6
1K
R7
1. Crossed schematic lines are not connected.
2. R4 value dependent on aux winding turns.
3. R1 is optional inrush limiting resistor.
4. U1 tab (pin 4) and D7 should have heatsinking clad pours.
5. Heavy lines indicate recommended ground plane areas.
6. L1A/L1B are Wurth 7447728102
7. U2 is Vishay SFH6156A-4 optocoupler or similar.
C11
0.1uF
50V
0.1uF
50V
4
3
U2
1 10K U3
2
R8
R10 C12 39K
21.5K 0.1
NCP431
R9
10K
20 Watt NCP1077 Power Supply
with Universal AC Input (Rev 4)
12 V Transformer Design
12V/2.0A, 65 kHz Version (Wurth Electronics # 750313861 Rev 1)
Core: E25/10/6 (812E250)
Primary A: 55 turns of 0.25mm mag wire
12V Secondary: 22 turns of 0.6mm Triple Insulated Wire (11 TPL, 2 layers)
Aux/Vcc: 22 turns of 0.15mm mag wire spiral wound over 1 layer
Primary B: 55 turns of 0.25mm mag wire
Primary Inductance (Pri A and B in series): 2 mH +/- 10% (gap in center leg)
Leakage Inductance (12Vsec & Aux shorted): 30 uH max
1
© 2013 ON Semiconductor.
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 Frank Cathell, e-mail: [email protected]
August 2013, Rev. 0
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2
DN05049/D
5V Circuit Schematic
R12
5.6K
J1
L1A
F1
1 mH
1.5A
C1
AC Input
T1
0.1uF
"X"
R1
4.7 ohms
3W
R2A
C2
0.1uF
"X"
L1B
3.3M
D1-D4
MRA4007
X4
C3
1 mH
5.6K
C4
6
1nF
1kV
8
D5
22uF
400V
U1
R2B
3.3M
R13
R3
68K
1/2W
Primary
Ground
Plane
4
1N4937
NCP1077
(65 kHz)
C5
22uF
25V
C13
47
1nF
D7
3
2
1
10
R11
J2
C9A C9B
+
5
SB80W06T C10
R4
2.7K
C7
1nF
MMSD
103
R5
D6
C6
10
4.7uF
50V
1
7
Secondary
Ground
Plane
9
5Vout
_
2,200uF, 6.3VV
C8
1nF "Y1"
NOTES:
R6
240
R7
1. Crossed schematic lines are not connected.
2. R4 value dependent on aux winding turns.
3. R1 is optional inrush limiting resistor.
4. U1 tab (pin 4) and D7 should have heatsinking clad pours.
5. Heavy lines indicate recommended ground plane areas.
6. L1A/L1B are Wurth 7447728102
7. U2 is Vishay SFH6156A-4 optocoupler or similar.
C11
0.1uF
50V
0.1uF
50V
4
3
U2
1 10K U3
2
R8
R10 C12 10K
21.5K 0.1
NCP431
R9
10K
20 Watt NCP1077 Power Supply
with Universal AC Input (Rev 4)
5 V Transformer Design
5V/4A, 65 kHz Version (Wurth Electronics # 750313860 Rev 01)
Core: E25/10/6 (812E250)
Primary A: 55 turns of 0.25mm mag wire
5V Secondary: 11 turns bifilar of 0.6mm Triple Insulated Wire (2 layers)
Aux/Vcc: 25 turns of 0.15mm mag wire spiral wound over 1 layer
Primary B: 55 turns of 0.25mm mag wire
Primary Inductance (Pri A and B in series): 2 mH +/- 10% (gap in center leg)
Leakage Inductance (5Vsec & Aux shorted): 40 uH max
August 2013, Rev. 0
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3
DN05049/D
Efficiency vs Load Curves
Typical Standby (no load) Input Power
120 Vac:
230 Vac:
30 mW
64 mW
August 2013, Rev. 0
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4
DN05049/D
Full Load Output Ripple @ 120 Vac Input
12Vout
5Vout
Note: The demo boards under test do not contain an output L/C ripple filter (see
schematics above). The output ripple can be further reduced another half-order of
magnitude if necessary by the addition of a 4.7 uH inductor followed by a 100 uF
capacitor.
August 2013, Rev. 0
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5
DN05049/D
MOSFET Drain Voltage
Full Load – 120Vac Input
Light Load – 120 Vac Input
August 2013, Rev. 0
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6
DN05049/D
EMI Profile - Quasi-peak (blue) and Average (red)
dBuV
NCP1077 Flyback
120Vac input, 12Vout, 20 watt load
80
70
60
EN 55022; Class B Conducted, Quasi-Peak
50
40
EN 55022; Class B Conducted, Average
Pk
30
20
Average
10
0
-10
-20
1
10
8/7/2013 12:21:37 PM
August 2013, Rev. 0
(Start = 0.15, Stop = 30.00) MHz
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7
DN05049/D
Bill of Materials for 15W/20W NCP1076/1077 Flyback (Rev4)
h
8/7/2013
Designator Qty
D7 (12Vout)
D7 (5Vout)
D1, 2, 3, 4
D5
D6
U3
U2
U1
1
1
4
1
1
1
1
1
Description
Value
Schottky diode
Schottky diode
Diode - 60 Hz,
Diode - fast recov
Signal diode
Programmable zener
Optocoupler
Switcher IC - NCP1077/1076
3A, 100V
8A, 60V
1A, 800V
1A, 600V
100mA, 250V
2.5V
CTR >/= 0.5
65 kHz
Tolerance
Footprint
Manufacturer
Manufacturer Part Number
SMC
DPak
SMA
axial lead
SOD-123
SOIC8 / SOT23
4-pin
SOT223
ON Semi
ON Semi
ON Semi
ON Semi
ON Semi
ON Semi
Vishay or NEC
ON Semi
MBRS3100
SB80W06T or MBRD660CT
MRA4007
1N4937
MMSD103
NCP431A
Digikey P/N = PS2561BL-1
NCP1077ST65
C1, C2
2
"X" cap, box type
100nF, X2
LS = 15 mm
Rifa, Wima
C8
1
"Y1" cap, disc type
1nF, Y1
LS = 7.5 mm
Rifa, Wima
C4
C7, C13
C10, 11, 12
C3
C6
C5
C9A,B (12V)
C9A,B (5V)
1
2
3
1
1
1
2
2
Ceramic cap, disc
Ceramic cap, monolythic
Ceramic cap, monolythic
Electrolytic cap
Electrolytic cap
Electrolytic cap
Electrolytic cap
Electrolytic cap
1 nF, 1kV
1 nF, 100V
100nF, 50V
22uF, 400/450V
4.7uF, 50Vdc
22uF, 25V
1000uF, 16V
2200 or 3300uF, 6.3V
5%
10%
10%
10%
10%
10%
10%
10%
LS = 7.5 mm
1206
1206
LS=7.5mm, D=16mm
LS=2.5 mm, D=6.3mm
LS=2.5mm, D=6.3mm
LS=5mm, D=12.5mm
LS=5mm, D=12.5mm
Rifa, Wima
AVX, Murata
AVX, Murata
UCC, Panasonic
UCC, Panasonic
UCC, Panasonic
UCC, Panasonic
UCC, Panasonic
Digi-Key P/N = 399-5426-ND
Digikey P/N = BC2374-ND, Mouser
P/N = 75-WKP102MCPEJ0KR
Digi-Key P/N = 478-4227-ND
TBD
Digi-Key P/N = 311-1179-1-ND
Digikey P/N = P5877-ND
Digi-Key P/N = 565-1105-ND
Digi-Key P/N = 565-1056-ND
Digi-Key P/N = 565-1664-ND
TBD
R1
R3
R2A,R2B
R10
R11
R5
R4
R7, R9
R12, R13
R6 (12Vout)
R6 (5Vout)
R8 (12Vout)
R8 (5Vout)
1
1
2
1
1
1
1
2
2
1
1
1
1
Resistor, 3W, Wire wound
Resistor, 0.5W, metal film
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Resistor, 1/4W SMD
Use jumper wire
68K, 0.5W
3.3 Meg
21.5K
47 ohms
10 ohms
2.7K
10K
5.62K
1K
240 ohms
38.3K
10K
10%
10%
1%
1%
1%
1%
1%
1%
1%
1%
1%
1%
1%
LS=7.5mm, D=7mm
Axial lead; LS=12.5mm
SMD 1206
SMD 1206
SMD 1206
SMD 1206
SMD 1206
SMD 1206
SMD 1206
SMD 1206
SMD 1206
SMD 1206
SMD 1206
Ohmite, Dale
Ohmite, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
AVX, Vishay, Dale
Digi-Key P/N = 4.7AECT-ND
Mouser = 71-FP01/268K0G5605EK
Digi-Key P/N = 541-3.30MFCT-ND
Digi-Key P/N = 541-21.5KFCT-ND
Digi-Key P/N = 541-47.0FCT-ND
Digi-Key P/N = 541-10.0FCT-ND
Digi-Key P/N = 541-2.70KFCT-ND
Digi-Key P/N = 541-10.0KFCT-ND
Digi-Key P/N = 541-5.62KFCT-ND
Digi-Key P/N = 541-1.00KFCT-ND
Digi-Key P/N = 541-240FCT-ND
Digi-Key P/N = 541-38.3KFCT-ND
Digi-Key P/N = 541-10.0KFCT-ND
TR-5, LS=5mm
See Wurth Drawing
See Mag Drawing
See Mag Drawing
LS = 0.2"
Minifuse
LS=5mm, D=8mm
Wurth Magnetics
Wurth Magnetics
DigiKey
Digi-Key P/N = WK4253BK-ND
7447728102
750313861 Rev 1
750313860 Rev 1
# 281-1435-ND
F1
1
Fuse, TR-5 style
L1A/B
1
Inductor (EMI choke)
T1 (12Vout) 1
Transformer
T1 (5Vout) 1
Transformer
J1, J2
2
Screw Terminal
Blue indicates part change with Vout change
August 2013, Rev. 0
1.5A
1 mH, 500 mA
E25/10/6 core
E25/10/6 core
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Substitution Lead
Comments
Allowed
Free
No
No
No
No
No
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
12V version
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
8
DN05049/D
References
ON Semiconductor data sheet for NCP1076/1077 monolithic switcher.
ON Semiconductor Design Notes DN05018, DN05043, DN05048
ON Semiconductor Application Note AND8489/D
ON Semiconductor Flyback Transformer Design Tool:
(http://www.onsemi.com/PowerSolutions/supportDoc.do?type=tools&rpn=NCP1075)
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 Frank Cathell, e-mail: [email protected]
August 2013, Rev. 0
www.onsemi.com
9