DN05078/D Design Note – DN05078/D Universal AC Input, 5V3A Output, 15 Watt Charger Device Application Input Voltage Output Power Topology I/O Isolation NCP1361BABAY Mobile, tablet Charger, adapter 90 to 264 Vac 15W Quasi Resonant Flyback Yes Item Rated Input Voltage Input Voltage Range Input Frequency Range Inrush Current Average Efficiency Full Load Efficiency 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 >84% >86% <30mW 5V~5.5V, 5V at 3A 3A >15W <80mV <60ms <1.5s <6.4V 4.3V~5.5V Test Condition 264Vac and 3A load Measured at board end via USB connector Measured at board end via USB connector 115Vac&230Vac 90Vac~264Vac and 0~3A 90Vac~264Vac 90Vac~264Vac 90Vac~264Vac, 1uF+0.1uF CAP@E-load At No/Full load,115Vac&230Vac 90Vac~264Vac and 0~3A At 1m USB cable end 0A-3A, 0.25A/us,10ms cycle Circuit Description This design note describes a 15 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 current and secondary constant voltage regulation utilizing ON semiconductor’s new NCP1361 current mode controller which is in TSOP6 package. This Design Note provides the complete circuit schematic details, layout, test data and BOM for 5.1 volts, 3 amps power supply. 1. Input circuit Rectifier, filter and EMC circuit formed by D1, C2, C3, L1, L2 and L3, NTC is 10ohm negative temperature coefficient resistor to provide inrush protection, F1 provides short-circuit protection when large AC input current occurs. July 2015, Rev. 0 2. NCP1361 control circuit NCP1361 is a Hybrid controller without a high voltage startup current source, so it need external startup resistor, startup resistor R16 and R24 can be connected between high voltage rail directly and Pin1. R8, and R9 consists of voltage simple network to set output voltage, C6 is a delayed capacitor to delay switching on to valley. R4 and R5 is a current sensing resistor to decide how much current can be set, R3 and CS pin parasitic capacitor consists of a filter to filter current spike. R10, R20, R21, R22, C7, C8, C9, U2 and U4 consist of simple, feedback and a type II compensation network to provide voltage feedback control loop compensation. www.onsemi.com 1 DN05078/D R6, D6 and C4 consist of Vcc supply circuit, Key Features R6 can adjust Vcc voltage and also prevent D6 from a inrush current. An RCD-R clamp Primary Side CC Regulation and consisting of R1, R2, C3, and D5 limits drain Secondary CV Regulation voltage spikes caused by leakage Quasi-Resonant current mode control with inductance, resistor R1 has a relatively large Valley Switching value to prevent any excessive ringing on Valley lockout avoids audible noise at the drain voltage waveform and R3 can limit valley jumping operation the reverse recovery current through D5. External 10M startup resistor Built in 4ms soft start 3. Output synchronous rectification and filter 80kHz maximum clamp frequency Synchronous rectification consist of Q1, U3 operation and external components, a Schottky barrier Adjustable voltage control loop type diode is parallel with MOSFET to reduce compensation power loss during dead time, and filtered by Wide Operation VCC range (up to 30 V) C13, C14 and C5. In this application, C13 and Cycle by cycle current limit C14 have sufficiently low ESR characteristics Support external 2200Uf startup to allow meeting the output voltage ripple Built in Vcc OVP (typical 26v) requirement without adding an LC post filter. Built in output UVP in CC mode (3V+/6.7%) C12 and R12 is snubber network of Q1 to Output OCP, SCP, OVP and controller eliminate excessive ringing on secondary OTP function voltage waveform. R13 is a dummy load to CS pin open and short protection prevent output voltage rising at no load. Vs pin open and short protection Meet COC V5 Tier 2 Lowest working voltage of U3 is 4.2V, in order 100pF Y capacitor to meet 3V lowest voltage output during CC “Travel Adapter” (TA) form factor mode an external Vcc supply circuit is Size: 43.5mm x 35mm x 15mm needed, this circuit is consisted of R23, R37, C16, C17, D2, ZD1 and Q3. D3 and D4 provide a Vcc supply in parallel and Vcc supply is provided by D4 at no load to reduce the standby power at no load. U3 also provides automatic light-load and disable mode which can clamp MOSFET drive signal level down to zero and then disable the controller at light load, this light load detection consist of R26, R27, R29, C11, C18 and D9, the difference of Vcc-VLLD will drop when light load is applied, for details, pls see page 35 on NCP4305 datasheet. July 2015, Rev. 0 www.onsemi.com 2 DN05078/D Circuit Schematic PCB layout Demoboard Photo July 2015, Rev. 0 www.onsemi.com 3 DN05078/D Standby Power at No Load 35 32.5 30 27.5 25 Pin(mW) 22.5 20 17.5 15 12.5 10 7.5 5 2.5 0 90 115 132 180 230 264 Vac Average Efficiency Between 25%, 50%, 75% and 100% Load 88 87 Efficiency(%) 86 85 84 83 82 81 80 90 115 230 264 Vac July 2015, Rev. 0 www.onsemi.com 4 DN05078/D Efficiency Vs Load Curves 90 87.5 85 Efficiency(%) 82.5 80 115Vac 77.5 230Vac 90Vac 75 264Vac 72.5 70 67.5 0.3 0.75 1.5 2.25 3 Io(A) I-V Curves 5.5 5 4.5 4 Vo(V) 3.5 3 115Vac 2.5 230Vac 90Vac 2 264Vac 1.5 1 0.5 0 0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 Io(A) July 2015, Rev. 0 www.onsemi.com 5 DN05078/D Output Ripple Voltage (Test condition: tested at E-load with 1m cable, 1uF E-CAP and 0.1uF ceramic in parallel) 90Vac and 3A load 115Vac and 3A load 230Vac and 3A load 264Vac and 3A load Transient Response Test Condition: 0A-3A, 250mA/us 10ms cycle, 230Vac July 2015, Rev. 0 Test Condition: 0A-1.5A, 250mA/us 10ms cycle, 230Vac www.onsemi.com 6 DN05078/D OVP SCP Test condition: 264Vac, no dummy load Startup Time 90Vac and 3A CC load Test condition: SC at board end Startup with Ext. 2200Uf capacitor 90Vac, 3A CC load with Von=0V Output Voltage Rise Time 115Vac and 3A CC load July 2015, Rev. 0 230Vac and 3A CC load www.onsemi.com 7 DN05078/D Output Voltage Overshoot 230Vac and no load 230Vac and 3A CC load MOSFET Drain Voltage Startup at 264Vac and 3A CC load Inrush Current Work at 264Vac and 3A CC load Secondary Diode Reverse Voltage And Syn. drive 264Vac and 3A CC load July 2015, Rev. 0 264Vac and 3A CC load www.onsemi.com 8 DN05078/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 Qty Referen Type 2 1 1 1 1 2 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 July 2015, Rev. 0 Part Name MFR Value C5 C15 Ceramic Capacitor Std std 0.1uF C17 Ceramic Capacitor Std std 0.1uF C18 Ceramic Capacitor Std std 0.1uF C7 Ceramic Capacitor Std std 0.22uF C4 Ceramic Capacitor C2012X7R1I155K TDK 1.5uF C8-9 Ceramic Capacitor Std std 100pF CS65-B2DA101KYNTDK 100pF,Y1 C10 Ceramic Capcitor C6 Ceramic Capacitor Std std 10pF C12 Ceramic Capacitor C1608C0D2A102J TDK 1nF,100v C11 Ceramic Capacitor C1608X6S1I105K TDK 1uF C16 Ceramic Capacitor C1608X6S1I105K TDK 1uF 560pF,630V C3 Ceramic Capcitor C3216C-G2J561TDK D1 Bridge rectifier LaB6S FSC 1A,600V BAS20IT1D ON 0.2A,200V D2,D3,D6,DSwitching diode D4 Schotty diode BAT54IT1D ON 0.2A,30V D5 Standard rectifier DFLR1600 Diodes 1A,600V D7 Schotty rectifier NTS260SFT1D ON 2A,60V D8 Switching diode BAS20IT1D ON 0.2A,200V UtZ2012E102-1R5 Shunlord/TDK L3 Ferrite bead Wurth-aidcon 500uI L1 Common filter 150-1327 F1 aicro Fuse 20T-016I Iollyfuse 1.6A, 250Vac Q3 NtN Transistor aaBT3904LT1D ON U2 Voltage reference NCt431ACSNT1D ON NCt1361BABAYSN ON U1 tSR Controller U3 Syn. rectified controller NCt4305AaNTWDON Q2 NaOSFET SW6N70 SAaWIN 6A, 700V NTC NTC StNL05D100aBI Shunlord 10ohm U4 Optical coupler tS2701-1 NEC Axial leaded fixed inductor7447462221 Wurth 220uI L2 T1 Transformer 750342872 WE-midcon R19 Resistor Std Std 10 R8 Resistor Std Std 100K R18 Resistor Std Std 10k R21 Resistor Std Std 10k www.onsemi.com Package Description 603 603 603 603 805 603 Lead type 603 603 603 603 1206 aicro-DIt SOD323 SOD323 SOD123FL SOD123-2 SOD323 805 TI type Axial lead SOT23 SOT23 TSOt-6 DFN8 DtAK lead type SOt Lead type TI type 603 805 603 603 Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, 50V, 10% Safety standard approved,10% Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, SaD, 5% Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, 50V, 10% Capacitor, Ceramic, Chip, 5% Bridge Rectifier, 600V, 1A Switching diode, SaD Schotty diode, SaD Standard Rectifier, 1A, 600V Schotty Rectifier, 2A, 60V Switching diode, SaD 600ohm @100aIz T type,6.3x3x3,dual-wire in parallel aicro Fuse, 1.6A/250V Deneral NtN Transistor, SaD trogrammable precision reference tSR Controller, TSOt-6 Syn. Rectified Controller NaOS, 6A, 700V, DtAK NTC, 10ohm, diameter:5mm optical coupler, standard SOt package Axial leaded fixed inductor EFD20-10tin Resistor, Chip, 1/8W, 1% Resistor, Chip, 1/5W, 1% Resistor, Chip, 1/8W, 1% Resistor, Chip, 1/8W, 1%, 9 DN05078/D BOM(Con’t) Item 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 Qty Referen Type 1 1 1 1 1 2 1 2 1 1 1 2 2 2 1 1 1 2 1 2 2 2 1 1 1 July 2015, Rev. 0 R3 R6 R17 R9 R26 R11,R23 R22 R27,R29 R20 R10 R37 R28,R30 R4 R5 R2 R12 R1 R16,R24 R13 R14,R15 C1,C2 C13,C14 Q1 J1 ZD1 Part Name MFR Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Resistor Std Std Electrolytic capacitorERK2GM150G12OT AiSHi Electrolytic solid capPX681M6R3E090P CapXon NTMFS5C612NLT1G ON MOSFET USB connector USB A Type Std Zener MM3Z5V6T1G ON www.onsemi.com Value Package 1k 2.2 20k 27k 2k 47 470 47k 50k 51k 51k NA 1.2 1 150 20 300k 5.1M NA NA 15uF,400V 680uF,6.3V 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 603 Resistor, Chip, 1/8W, 805 Resistor, Chip, 1/5W, 805 Resistor, Chip, 1/5W, 1206 Resistor, Chip, 1/4W, 805 Resistor, Chip, 1/5W, 1206 Resistor, Chip, 1/4W, 1206 Resistor, Chip, 1/4W, 805 Resistor, Chip, 1/5W, 603 Resistor, Chip, 1/8W, 10mm(die.)x12size,10mmx12.5mm 6.3mm(die.)x9size, 6.3mmx9mm SO8FL MOSFET, NChan, 60V TH type USB connector, Type A SOD323 GENERIC ZENER-DIODE 5.6V Description 10 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% 1% DN05078/D References ON Semiconductor datasheet for NCP1361/6 CC/CV primary side PWM current mode controller. ON Semiconductor design note DN05073, DN05074. 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] July 2015, Rev. 0 www.onsemi.com 11