DN05001/D Design Note – DN05001/D 140 W LCD TV PSU Device NCP1927 Application LCD TV Input Voltage Output Power Topology Outputs 140 W CrM PFC + Flyback 3 90 to 265 Vac Output Specifications Output Voltage Maximum Current Output 1 Output 2 Output 3 390 VDC 250 mA 5 VDC 2A 12 VDC 2.5 A Average Efficiency Full Load Efficiency No Load Input Power Power Factor Startup Time >82% >85% <150 mW >0.95 <2 s Circuit Description Key Features This demonstration board targets a flat panel TV power supply application with a power capability of up to 140 W. It is built around the NCP1927, a combination power factor correction (PFC) controller and flyback controller optimized for use in flat panel TVs. The NCP1927 includes all the necessary features to implement a highly efficient and compact power supply. The built-in sequencing between the PFC and flyback modules allows for a much simpler system design than that typically achieved when using two separate controllers. For a detailed description of the NCP1927 and recommendations on how to use this controller, please refer to the NCP1927 datasheet and other related documents at www.onsemi.com. Autorecovery Vcc overvoltage protection Shutdown control to disable the entire controller Standby control to disable just the PFC Primary and secondary side PFC_OK output to enable the backlight inverter Input common and differential mode EMI filters for agency EMI compliance NTC thermistor for inrush current limiting Pi-network filters on all outputs for low noise and ripple Flyback and PFC transformers designed with common industry standard ferrite cores (EER28 and EFD30) 1 1 © 2011 ON Semiconductor. Disclaim er: ON Semiconductor is providing this design note “AS IS” and does not assume any liability ar ising 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 c ircuit implementation and the recipient assumes all liability and risk associated w ith its use, including, but not limited to, compliance w ith all regulatory standards. ON Semiconductor may change any of its products at any time, w ithout notice. Design note created by Alan Finkel, e-mail:[email protected] May 2011, Rev. 0 www.onsemi.com 1 DN05001/D 900.0 800.0 Standby Power (mW) 700.0 600.0 500.0 115 Vac 400.0 230 Vac 300.0 200.0 100.0 0.0 0 100 200 300 400 500 Output Load (mW) Figure 1. Standby Power vs. Load (Applied to +5 V Output Only) 93% 92% 91% Efficiency 90% 89% 90 Vac 115 Vac 88% 230 Vac 87% 265 Vac 86% 85% 84% 20% 30% 40% 50% 60% 70% 80% 90% 100% Percentage of 140 W Output Load Figure 2. Efficiency vs. Load (All Outputs Loaded Equally) May 2011, Rev. 0 www.onsemi.com 2 DN05001/D 1.00 0.98 Power Factor 0.96 0.94 90 Vac 115 Vac 0.92 230 Vac 265 Vac 0.90 0.88 0.86 20% 30% 40% 50% 60% 70% 80% 90% 100% Percentage of 140 W Output Load Figure 3. Power Factor vs. Load (All Outputs Loaded Equally) 90 Vac 115 Vac 1.31 sec 230 Vac 0.46 sec 265 Vac 0.41 sec 0.95 sec Table 1. Startup Time May 2011, Rev. 0 www.onsemi.com 3 DN05001/D Figure 4. 140 W LCD TV PSU Front Figure 5. 140 W LCD TV PSU Back May 2011, Rev. 0 www.onsemi.com 4 DN05001/D Schematic2 May 2011, Rev. 0 www.onsemi.com 5 DN05001/D 3 Bill of Materials 05/17/2011 Designator Quantity Description Value Tolerance Footprint Manufacturer Manufacturer Part Number Substitution Allowed Lead Free L1 L2 1 1 Inductor, Common-Mode Choke Inductor, Line Choke 12 mH 127 uH 10% 10% Toroid Toroid PULSE PULSE PH9080NL PH9091NL No No Yes Yes L100 1 Inductor, PFC 200 uH 10% EFD30 WURTH ELEKTRONIK 750370081 No Yes T200 L101,L200,L201 1 3 Transformer, Flyback Inductor 1.0 mH 10 uH 10% 10% EER28 Radial WURTH ELEKTRONIK WURTH ELEKTRONIK 750811634 7447455100 No No Yes Yes CN1 CN100 1 1 Connector, AC Inlet Connector, 5 Pos. - - - QUALTEK Tyco-AMP 703W-00/52 640445-5 Yes Yes Yes Yes CN101 1 Connector, 4 Pos. - - - JST-XH B4B-XH Yes Yes CN201 CN200 1 1 Connector, 5 Pos. Connector, 12 Pos. - - - JST-XH JST-XH B5B-XH B12B-XH Yes Yes Yes Yes C102 1 Capacitor, Ceramic, SMD 390 pF 10% 0603 AVX 06035C391KAT2A Yes Yes C105, C106 C109 2 1 Capacitor, Ceramic, SMD Capacitor, Ceramic, SMD 1 nF 330 pF 10% 10% 0603 0603 AVX AVX 06035C102KAT2A 06035C331KAT2A Yes Yes Yes Yes C110 C108 1 1 Capacitor, Ceramic, SMD Capacitor, Ceramic, SMD 100 pF 10 nF 10% 10% 0603 0603 AVX AVX 06035C101KAT4A 06035C103KAT2A Yes Yes Yes Yes C112 C101,C113, C211,C212 1 Capacitor, Ceramic, SMD 1 uF 10% 0603 Taiyo Yuden UMK107BJ105KA-T Yes Yes 4 Capacitor, Ceramic, SMD 100 nF 10% 0603 AVX 06035C104KAT2A Yes Yes C206 C103 1 1 Capacitor, Ceramic, SMD Capacitor, Ceramic, SMD 100 nF 680 nF 10% 10% 0805 0603 AVX AVX 08055C104KAT2A 0603ZD684KAT2A Yes Yes Yes Yes C104 C3,C4,C200, C201,C300 1 Capacitor, Ceramic, SMD 1 uF 10% 0603 AVX 0603ZD105KAT2A Yes Yes 5 Capacitor, Ceramic, X1Y1 1 nF 20% Radial AVX 61V102MCECT Yes Yes C1,C2 C5,C6 2 2 Capacitor, MKP, X2 Capacitor, MKP 100 nF 470 nF 20% 10% Radial Radial EPCOS EPCOS B81130C1104M B32672Z4474K000 Yes Yes Yes Yes C116,C407,C408 C202,C204 3 2 Capacitor, MKP Capacitor, Electrolytic 10 nF 680 uF 3% 20% Radial Radial Panasonic - ECG United Chemi-Con ECW-F6103HL EKZE350ELL681MK20S Yes Yes Yes Yes C115,C209,C210 3 Capacitor, Electrolytic 47 uF 20% Radial Panasonic - ECG ECA-1HM470 Yes Yes C114 1 Capacitor, Electrolytic 1 uF 20% Radial Panasonic - ECG ECA-1HM010 Yes Yes 3 © 2011 ON Semiconductor. Disclaim er: ON Semiconductor is providing this design note “AS IS” and does not assume any liability arising from its use; nor does ON Se miconductor 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 ris k associated w ith its use, including, but not li mited to, compliance w ith all regulatory standards. ON Semiconductor may change any of its products at any time, w ithout notice. Design note created by Alan Finkel, e-mail:[email protected] May 2011, Rev. 0 www.onsemi.com 6 DN05001/D C107 C100 1 1 Capacitor, Electrolytic Capacitor, Ceramic, SMD 100 uF open 20% - Radial 0603 United Chemi-Con - EKXG451ELL101MM40S - Yes - Yes - C111,C207,C208 3 Capacitor, Ceramic, SMD open C203,C205 F1 R110,R111, R113,R127, R133,R134,R135 R112,R209, R130,R136,R140 R125,R128 2 1 Capacitor, Electrolytic Fuse, Leaded open 3A - 0805 - - - - - Radial Axial 2AG Littelfuse 0224003.HXP Yes Yes 7 Resistor, SMD 10 Ohm 1% 0603 Vishay/Dale CRCW060310R0FKEA Yes Yes 5 2 Resistor, SMD Resistor, SMD 10 kOhm 0 Ohm 1% 1% 0603 0603 Vishay/Dale Vishay/Dale CRCW060310K0FKEA CRCW06030000Z0EA Yes Yes Yes Yes R132 R107 R131,R137, R202,R206,R400 R205 R108,R119A, R208 1 Resistor, SMD 100 Ohm 1% 0603 Vishay/Dale CRCW0603100RFKEA Yes Yes 1 Resistor, SMD 470 Ohm 1% 0603 Vishay/Dale CRCW0603470RFKEA Yes Yes 5 1 Resistor, SMD Resistor, SMD 1 kOhm 698 Ohm 1% 1% 0603 0603 Vishay/Dale Vishay/Dale CRCW06031K00FKEA CRCW0603698RFKEA Yes Yes Yes Yes R203,R204 R129 3 Resistor, SMD 2.49 kOhm 1% 0603 Vishay/Dale CRCW06032K49FKEA Yes Yes 2 1 Resistor, SMD Resistor, SMD 4.75 kOhm 6.04 kOhm 1% 1% 0603 0603 Vishay/Dale Vishay/Dale CRCW06034K75FKEA CRCW06036K04FKEA Yes Yes Yes Yes R210 1 Resistor, SMD 12.7 kOhm 1% 0603 Vishay/Dale CRCW060312K7FKEA Yes Yes R106 R105 1 1 Resistor, SMD Resistor, SMD 20 kOhm 49.9 kOhm 1% 1% 0603 0603 Vishay/Dale Vishay/Dale CRCW060320K0FKEA CRCW060349K9FKEA Yes Yes Yes Yes R404 R114 1 1 Resistor, SMD Resistor, SMD 22.1 kOhm 33.2 kOhm 1% 1% 0603 0603 Vishay/Dale Vishay/Dale CRCW060322K1FKEA CRCW060333K2FKEA Yes Yes Yes Yes R120A R1,R2,R3,R401, R402,R403 R121,R122, R123,R301 1 Resistor, SMD 40.2 kOhm 1% 0603 Vishay/Dale CRCW060340K2FKEA Yes Yes 6 Resistor, SMD 1.00 MOhm 1% 0805 Vishay/Dale CRCW08051M00FKEA Yes Yes 4 Resistor, SMD 1.05 MOhm 1% 0805 Vishay/Dale CRCW08051M05FKEA Yes Yes R115,R116,R117 R118 3 1 Resistor, SMD Resistor, SMD 1.65 MOhm 1.69 MOhm 1% 1% 0805 0805 Vishay/Dale Vishay/Dale CRCW08051M65FKEA CRCW08051M69FKEA Yes Yes Yes Yes R200,R201 2 Resistor, Metal Film 100 Ohm 5% Axial, 1/2 W Stackpole Electronics RSMF12JT100R Yes Yes R124A,R124B R109 2 1 Resistor, Metal Film Resistor, Metal Film 33 kOhm 0.10 Ohm 5% 5% Axial, 2 W Axial, 2 W Stackpole Electronics Stackpole Electronics RSMF2JT33K0 RSMF2JTR100 Yes Yes Yes Yes R138 R104,R119B, R120B,R126, R139,R207,R211 R100,R101, R102,R103 1 Resistor, Metal Film 0.39 Ohm 5% Axial, 2 W Stackpole Electronics RSMF2JBR390 Yes Yes 7 Resistor, SMD open - 0603 - - - - 4 Resistor, SMD open - 0805 - - - - RT1 1 Inrush Current Limiter 10 Ohm 20% Radial EPCOS B57153S0100M000 Yes Yes RV1 BD01 1 1 Varistor Diode, Bridge Rectifier 470 V 600 V / 8 A 10% - Radial Thinking Electronic Diodes Inc. TVR10471KSY GBU806 Yes Yes Yes Yes D100 D102,D104,D106 1 3 Diode Diode, General Purpose 600 V / 3 A 100 V / 0.2 A - DO-201 SOD-123 ON Semiconductor ON Semiconductor 1N5406 MMSD4148 No No Yes Yes D200 1 Diode, Dual Schottky 100 V / 20 A - TO-220AB ON Semiconductor MBRF20100CTG No Yes D201 1 Diode, Dual Schottky 80 V / 20 A - TO-220AB ON Semiconductor MBRF20L80CTG No Yes May 2011, Rev. 0 www.onsemi.com 7 DN05001/D D103 D105 1 1 Diode, Rectifier Diode, Fast Recovery 1000 V / 1 A 600 V / 1 A - DO-41 DO-41 ON Semiconductor ON Semiconductor 1N4007 1N4937 No No Yes Yes D101 1 Diode, Ultrafast 500 V / 5 A - DO-201 ON Semiconductor MUR550APF No Yes ZD100 Q200 1 1 Diode, Zener Transistor, NPN 28 V - 5% - SOD-123 SOT-23 ON Semiconductor ON Semiconductor MMSZ5255BT1 BC848BLT1 No No Yes Yes Q101,Q103 Q102 2 1 Transistor, PNP Transistor, PNP - - SOT-23 SOT-23 ON Semiconductor ON Semiconductor BC807-25LT1 BC856ALT1 No No Yes Yes Q104 1 MOSFET, N-Channel 600 V / 4 A - TO220FP ON Semiconductor NDF04N60ZG No Yes Q100 Q201 1 1 MOSFET, N-Channel Transistor, NPN 500 V / 12 A open - TO220FP SOT-23 Infineon - SPA12N50C3 - No - Yes - IC100 1 - - SOIC-16 ON Semiconductor NCP1927 No Yes IC200 1 IC, Controller IC, Shunt Regulator (Install Backwards) 2.5 V 1% TO-92 ON Semiconductor TL431ACLPRPG No Yes IC101 PC300 1 1 IC, Shunt Regulator Optocoupler open - - TO-92 DIP-4 CEL PS2513-1-A Yes Yes PC301,PC400 2 Optocoupler - - CEL PS2501A Yes Yes CN401, CN402 HS1, HS4 2 2 Ground Lug Heat Sink 80 mm - DIP-4 3.175mm x 8mm 80mm Columbia-Staver TP207ST-80.0-12.5-NA-SP-01 Yes Yes Yes Yes HS2, HS3 2 Heat Sink 40 mm - 40mm Columbia-Staver TP206ST-40.0-15.0-NA-SP-01 Yes Yes Clip 4 Clip - - 12mm Columbia-Staver W950 Yes Yes May 2011, Rev. 0 www.onsemi.com 8