DN05039/D
Design Note – DN05039/D
A 15 Watt, Triple Output, Ultra Wide
Range AC Input Power Supply
Device
Application
NCP1251B
NCP431
E-Meters, Industrial
Equipment
Input Voltage
Output Power
Topology
I/O Isolation
85 to 520 Vac
15W Nominal,
20W Peak
Flyback
Yes
Other Specification
Output Voltage
Ripple (P/P Max)
Nominal Current
Max Current
Min Current
Output 1
Output 2
Output 3
Output 4
5.0 V
150 mV
2 Amps
2.5 Amps
0
5.0 V
100 mV
100 mA
100 mA
0
12.0 V
150 mV
400 mA
700 mA
10 mA
N/A
N/A
N/A
N/A
N/A
PFC (Yes/No)
Minimum Efficiency
Inrush Limiting / Fuse
Operating Temp. Range
Cooling Method /
Supply Orientation
Signal Level Control
No
70% at 15W out and 480Vac input
Yes
-40 ~ 85C
Convection
NA
Others All outputs isolated from each other; linear regulator options for output channels 2 and 3.
Circuit Description
The Design Note provides the technical details for a 15
watt nominal, 20 watt peak output power supply design
which will operate over a 6:1 AC input line range and
provide 3 fully isolated output voltages. The channel 1
output provides a dedicated 5 volt output at up to 2.5
amps. The second channel includes a 3-terminal
regulator so as to provide a highly regulated, low ripple,
low current output. In this demo board, a second 5 volt
rd
output with up to 100 mA is provided. The 3 channel is
a quasi-regulated 12 volt output which will provide up to
700 mA, however, the option for another 100 mA, 3terminal regulator is also provided in the event this
channel needs to have a highly regulated output.
The flyback power converter is designed around ON
Semiconductor’s NCP1251B current mode controller
(TSOP-6 package) and a 6 amp, 900 volt MOSFET. The
flyback operates in continuous conduction mode (CCM)
for most of the mid to upper load range. This mode was
chosen to allow optimization of the transformer design
and to achieve a turns ratio that would allow efficient
operation from 85 to 520 Vac input and still minimize
November 2012, Rev. 0
voltage stresses on the output rectifiers and the power
MOSFET. Although a heatsink is not used on the TO220 MOSFET Q1 in the demo board, it is recommended
that a small one be used on the device if continuous
operation at 15 watts is anticipated in an elevated
ambient environment.
This Design Note is essentially an extension of ON
Semiconductor Design Note DN05017 which describes a
10 watt, 12 volt output supply with an identical wide
range AC input.
Plots and ocilloscope screen captures are presented
below to illustrate performance examples.
Key Features
Input EMI filter for EN55022 conducted emission
compliance.
Over current and over voltage protection.
Excellent regulation with standard NCP431 and
optocoupler feedback scheme to NCP1251.
Three fully isolate outputs with 3-T regulator options on
outputs 2 and 3.
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1
DN05039/D
Schematic1
Jmp1
L1A
2.2M
2.2M
C1
10nF "X1"
L1B
2.2M
0.1uF
"X2"
C2B
820uH
1M
TVS1
390K
R2
14
43K
1W
3.3nF 1
2kV
1M
390K
D8
1N4937
x2
R7
C8
10nF
R9
1K C5
1nF
1
10 ohms
4
10uF
50V
_
470
16V
3.3K 0.1uF
50V
C9A C9B
+5V
C14
_
+5V/2A
_
2.2nF "Y1"
D7
R5
C13
C18
C10
D9
R8A/B
2 ohms
9
C19
1/2W
0.1uF
3300uF, 6.3V 0.1uF 0.1uF
C20A C20B
50V
x2
50V
50V
6
5
R17
3T reg
8
1K
U1
C12
+12V
3.3K
U4
11
MBRS3100
R10
2
D10
10K
MMSZ5254B NCP1251B
(27V)
3
6
10
R4D
1M
1000uF
25V
0.1uF
50V
470
16V
C15
MURA140
C17
C16
D11
13
MRA
4007
Z1
7
2
47uF
400V
R16
optional
3T reg
10
D5B
Q1
R4C MMSD4148
1M
D6
C3B
R6
U5
MURS240
D5A
R4B
47uF
400V
R3A R3B R3C
390K
R4A
C3A
R1B
C2A
D1-D4
MRA4007
X4
R1A
820uH
1.6A
480Vac
AC Input
C4
R1C
F1
T1
R12
3
MMSD
103T
10K
R11
12
R14
240
C6
U3
C7
220pF
R15
U2
4
1
15K
C11
27K
0.1
NCP431
R13
10K
3
2
NOTES:
1. Crossed lines on schematic are NOT connected.
2. U2 is NEC PS2561L-1 or equivalent optocoupler (CTR > 50%).
3. C1 is 480Vac rated ceramic disk capacitor ("X" or "Y" types OK)
4. L1A/L1B are Wurth 7447728215 components (820 uH, 500mA).
5. Output caps (C9A/B, C12, C15) are radial lead, low impedance types (UCC LXV series or similar).
6. R5 is for Vcc trimming (< 28Vmax), typically zero to 10 ohms.
7. R8A/B sets max output current.
8. TVS1 is optional transient voltage suppressor.
9. C15 & C16 should be 480Vac rated "Y1" cap.
10. Q1 is 900V or higher, 3A rated Mosfet.
11. Jmp1 is optional jumper if regulator U5 is not used.
12. See drawing for T1 details.
15 Watt, Triple Output NCP1251 Power Supply
with Ultra-Wide AC Input (Rev 4A)
November 2012, Rev. 0
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DN05039/D
MAGNETICS DESIGN DATA SHEET
Project / Customer: ON Semiconductor - 20 watt, Multiple output NCP1251 Flyback
Part Description: 20 watt flyback transformer, triple output (5V/8V/12V), 100 kHz
Schematic ID: T1
Core Type: EE20/10/6 ferrite core; 3C90 material or similar
Core Gap: Gap for 180 to 220uH across Primary A (pins 1 - 10)
Inductance: 800 uH total (+/- 10%) measured from pin 1 to pin 9 with pins 2 and 10 connected
Bobbin Type: 14 pin horizontal mount for EE20/10/6
Windings (in order):
Winding # / type
Turns / Material / Gauge / Insulation Data
Primary A (1 - 14)
28T of #28 mag wire over 1 layer (28 TPL). Insulate for
1 kV to next winding. Self leads to pins.
Vcc (3 - 12)
11 turns of #28 mag wire over 1 layer, spiral wound
over primary A. Self leads to pins.
Insulate to 1 kV to next winding with tape.
5V Secondary (8 - 9)
4 turns bifilar of #24 triple insulated wire over one.
layer (two strands) - spiral wind. Self leads to single pin
as shown in drawing below.
12V Secondary (7 - 10)
9 turns of #26 triple insulated wire spiral wound over
1 layer. Self leads to pins.
8V Secondary (6 - 11)
6 turns of #26 triple insulated wire spiral wound over
1 layer. Self leads to pins
NOTE: Despite having different turns, it would be desirable to wind the 12v and 8V secondaries semi bifilar if possible.
Primary B (2 - 13)
Same as Primary A. Insulate with tape and selfleads to pins.
Hipot: 2.5 kV from primaries & Vcc to secondaries for 1 minute.
Lead Breakout / Pinout
Schematic
14
Pri A
6
(Bottom View of Bobbin)
8V sec
1
13
Pri B
2
3
Vcc
12
November 2012, Rev. 0
11
7
14 12 11 9
12V sec
0.80" pin row separation
10
8
5V sec
(bifilar)
9
1 3
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8
Wurth Electronics Part
750313473 Rev 01
3
DN05039/D
Board Information
Dimensions: 100mm x 40mm
November 2012, Rev. 0
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DN05039/D
Efficiency versus Line Voltage
Efficiency vs Line Voltage
(Loading ratio: 5V1=65%, 5V2=0.4%, 12V=34%
% Efficiency
85
80
120
230
277
75
400
480
70
Effic at 15W Output
(%)
Effic at 10W Output
(%)
65
100
200
300
400
500
AC Input Voltage
12 Vout Load Regulation (5 Vout1 set at 1.5 amps)
November 2012, Rev. 0
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DN05039/D
Drain-to-Source Voltage Profile at 120 Vac, 230 Vac, and 480 Vac Inputs
(15 watts output; vertical scale is 100V per division)
November 2012, Rev. 0
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DN05039/D
Output Ripple (15 watt total load; 230 Vac input)
Output 1 (5 V at 2 A)
Output 2 (5 V at 100 mA)
Output 3 (12 V at 500 mA)
November 2012, Rev. 0
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DN05039/D
Conducted EMI Profile (EN55022, Level B, 240 Vac input)
dBuV
NCP1251 UWR Triple Output
240Vac
80
EN 55022; Class B Conducted, Average
70
60
50
40
30
20
10
0
Average
-10
-20
1
10
10/25/2012 11:14:51 AM
November 2012, Rev. 0
(Start = 0.15, Stop = 30.00) MHz
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DN05039/D
Bill of Materials for 20W, NCP1251, Triple Output, Ultra-Wide Input Flyback (Rev 4A)
h
9/7/2012
Designator
Qty Description
Value
Tolerance
Manufacturer
Manufacturer Part Number
SMC
SMA
SMB
TO-220
SMA
axial lead
SOD-123
SOD-123
SOD-123
SOT23
4-pin
TSOP-6
DPak3
DPak3
ON Semi
ON Semi
ON Semi
Fairchild / Infineon
ON Semi
ON Semi
ON Semi
ON Semi
ON Semi
ON Semi
Vishay or NEC
ON Semi
ON Semi
ON Semi
MBRS3100
MURA140T3G
MURS240T3G
FQP6N90C / IPP90R800C3
MRA4007
1N4937
MMSD4148A
MMSD103T1G
MMSZ5254B
NCP431A
SFH6156A-4 or PS2561L-1
NCP1251B
LM2931
TBD
Kemet
Rifa
Rifa, Wima
Rifa, Wima, Vishay
AVX, Murata
AVX, Murata
AVX, Murata
AVX, Murata
UCC, Panasonic
UCC, Panasonic
UCC, Panasonic
UCC, Panasonic
UCC, Panasonic
Digi-Key P/N = 399-5426-ND
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
Yes
Yes
D9
D10
D11
Q1
D1, 2, 3, 4, 8
D5A, D5B
D6
D7
Z1
U3
U2
U1
U4
U5
1
1
1
1
5
1
1
1
1
1
1
1
1
1
Schottky diode
UFR Diode
UFR Diode
Mosfet - 5A/900V
Diode - 60 Hz,
Diode - fast recov
Signal diode
Signal diode
Zener diode
Programmable zener
Optocoupler
Controller - NCP1251B
3-T regulator
3-T regulator
C2A, C2B
C1
C20A, B
C4
C5
C8
C10,11,14,17,18,19
C7
C3A, C3B
C6
C9A, C9B
C12, C15
C13, C16
2
1
2
1
1
1
6
1
2
1
2
2
2
"X2" cap, box type
100nF, 270Vac
"X1" cap, disc type
10nF, 440Vac
Y1 cap - ceramic disc
2.2nF, 2kV
Ceramic cap, disc (snubber)
3.3nF, 2kV
Ceramic cap, monolythic
1 nF, 50V
Ceramic cap, monolythic
10nF, 50V
Ceramic cap, monolythic
100nF, 50V
Ceramic cap, monolythic
220pF, 50V
Electrolytic cap
47uF, 400V
Electrolytic cap
10uF, 50Vdc
Electrolytic cap
3,300uF, 6.3V
Electrolytic cap
1000uF, 25V
Electrolytic cap
330 or 470uF, 16V
10%
5%
10%
10%
10%
10%
10%
LS=15mm
LS=7.5mm, D=21mm
LS = 7.5 mm
LS = 7.5 mm
1206
1206
1206
1206
LS=7.5mm, D=16mm
LS=2.5mm, D=6.3mm
LS=5mm, D=12.5mm
LS=5mm, D=12.5mm
LS=5mm, D=8mm
R2
R8A, R8B
R4A, R4B, R4C, R4D
R1A, R1B, R1C
R9, R10
R3A, B, C,
R5, R6
R11
R7,12,13
R14
R15
R16, R17
Jmp1
1
2
4
3
2
4
2
1
3
1
1
2
1
Resistor, 1W, metal film
Resistor, 1/2W 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
43K, 1W
2.0 ohms, 1/2W
1M, 1/4W
2.2M, 1/4W
1K
390K
10 ohms
240 ohms
10K
27K
15K
3.3K
Zero ohm
10%
10%
1%
1%
1%
1%
1%
1%
1%
1%
1%
1%
1%
Axial lead; LS=20mm
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
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TBD
TVS1
F1
L1A/B
T1 (12Vout)
J1
1
1
1
1
1
TVS (optional)
Fuse, S505 style (ceramic)
Inductor (EMI choke)
Transformer - E20/10/6 core
Screw Terminal
TBD
1.6A, 1500Vac
820 uH, 500 mA
14 pin bobbin
Axial Lead - LS= 12.5mm
Axial, LS-26mm, Dia=6mm
Dia = 10mm, LS = 5mm
See Mag Drawing
LS = 0.2"
ON Semi
Bussmann
Coilcraft
Wurth Magnetics
DigiKey
TBD
BK/S505-1.6R
RFB0810-1821L
750313473 Rev 01
# 281-1435-ND
November 2012, Rev. 0
3A, 100V
1A, 400V
2A, 400V
5A, 900V
1A, 1kV
1A, 600V
100mA, 100V
100mA, 250V
27V, 500mA
2.5V
CTR >/= 0.5
100 kHz
5V, 100 mA
TBD
5%
10%
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Substitution Lead
Allowed
Free
Footprint
9
No
Y
No
Y
No
Yes
No
No
No
No
No
No
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
DN05039/D
References:
ON Semiconductor NCP1251 Data Sheet: http://www.onsemi.com/pub_link/Collateral/NCP1251-D.PDF
ON Semiconductor Design Note DN05017: http://www.onsemi.com/pub_link/Collateral/DN05017-D.PDF
ON Semiconductor Design Note DN05012: http://www.onsemi.com/pub_link/Collateral/DN05012-D.PDF
ON Semiconductor Design Note DN05028: http://www.onsemi.com/pub_link/Collateral/DN05028-D.PDF
ON Semiconductor Design Note DN05029: http://www.onsemi.com/pub_link/Collateral/DN05029-D.PDF
ON Semiconductor Design Note DN05033: http://www.onsemi.com/pub_link/Collateral/DN05033-D.PDF
1
© 2012 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]
November 2012, Rev. 0
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