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. www.onsemi.com 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 www.onsemi.com 2 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 www.onsemi.com 6 8 Wurth Electronics Part 750313473 Rev 01 3 DN05039/D Board Information Dimensions: 100mm x 40mm November 2012, Rev. 0 www.onsemi.com 4 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 www.onsemi.com 5 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 www.onsemi.com 6 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 www.onsemi.com 7 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 www.onsemi.com 8 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% www.onsemi.com 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 www.onsemi.com 10