NCP1060FLBKGEVB NCP1060 Flyback Converter Evaluation Board User'sManual Universal AC Mains, Up to 7 Watt Isolated Power Supply Introduction www.onsemi.com EVAL BOARD USER’S MANUAL Pin LIM/OPP is connected through resistor R6 to auxiliary winding and sets over−power protection. Resistor R9 decreases maximal peak current. The frequency compensation of the feedback loop system is ensured by external capacitor C8 that is connected to the IC OTA output. This evaluation board manual describes a simple, low power (up to 7 W), universal AC mains Flyback converter. The converter provides constant voltage output. The supply can be used for powering utility electric meters, white goods or similar industrial equipments where isolation from the AC mains is required. The main benefits of provided solution are high efficiency, cost effectiveness and low no−load power consumption. The converter is utilizing monolithic ON Semiconductor switcher NCP1060 with integrated 34 W MOSFET in a PDIP7 package. The evaluation board manual provides complete circuit diagram and bill of materials. The current capability of provided converter is user adjustable. Key Features • • • • • Circuit Description • • The varistor R4 together with resistor R3 form simple protection that enhances application robustness against line over−voltage and voltage spikes. Resistor R3 also limits the inrush current when the power supply is connected to mains. The EMC filter is implemented to reduce conducted electromagnetic emissions to the mains. The Flyback converter itself is formed by the high voltage switching regulator IC1, transformer TR1, freewheeling diode D3 and coil L1 (L3). Capacitors C5, C6, C7 and C8 are used as the output filtering and energy storage bank. Resistor R1 and capacitor C2 for filter, C1, R2 and D2 are forming voltage clamp for the switcher drain. Opto−coupler OK1 (NCP431) is used in feedback network. Resistors R8, R12 and R13 form resistive divider and sets output voltage. Diode D7 and resistor R14 provide supply voltage for IC1 Vcc from auxiliary winding. The capacitor C10 is the energy storage element that keeps IC1 powered during light load conditions, when the switching frequency drops and energy from auxiliary winding refills Vcc capacitors less often. Universal AC Input Range (85 – 265 Vac) Input Filter for Conducted EMI Attenuation Very Low Standby and No−load Power Consumption Frequency Fold−back for Improved Efficiency at Light Load Inherent Over−current, Over−voltage and Over−temperature Protections Frequency Jittering for Better EMI Signature Adjustable Peak Current to Set the Required Level of Over−current Protection Table 1. Description Output Specification Output Voltage 12 Vdc Output Ripple < 25 mV @ Full Load Max Output Current 0.6 A Min Output Current 0A Efficiency See Efficiency Charts Input Protection Fuse Operating Temperature Range Cooling Method 0°C to +50°C Passive Cooling No−load Power Consumption < 75 mW @ 85 − 265 Vac Table 2. Device Application Input Voltage Output Power Topology I/O Isolation NCP1060AP060G White Goods, E−Meters 85 to 265 Vac 5 to 7 W Flyback Yes © Semiconductor Components Industries, LLC, 2016 January, 2016 − Rev. 0 1 Publication Order Number: EVBUM2345/D NCP1060FLBKGEVB CIRCUIT DIAGRAM L1: Würth elektronik − part No.: 744025002 L2: Würth elektronik − part No.: 768772102 L4: Würth elektronik − part No.: 744862120 TR1: Würth elektronik − part No.: 750370026 Figure 1. Circuit Diagram EVALUATION BOARD Figure 2. Evaluation Board − Top Side Figure 3. Evaluation Board − Bottom Side www.onsemi.com 2 NCP1060FLBKGEVB Figure 4. Conducted Emission Quasi−peak dBmV (Domestic) Figure 5. Efficiency vs. Output Load Curves www.onsemi.com 3 NCP1060FLBKGEVB Figure 6. No−load Power Consumption vs. Line Input Curves OUTPUT RIPPLE VOLTAGE Figure 7. Input Voltage 85 Vac and 0.4 A Load Figure 8. Input Voltage 110 Vac and 0.4 A Load www.onsemi.com 4 NCP1060FLBKGEVB Figure 9. Input Voltage 230 Vac and 0.4 A Load Figure 10. Input Voltage 265 Vac and 0.4 A Load TRANSIENT RESPONSE Vo Vo Io Io Figure 11. Test Condition: 30−400 mA, 28 ms Cycle, 110 Vac Figure 12. Test Condition: 30−400 mA, 28 ms Cycle, 230 Vac www.onsemi.com 5 NCP1060FLBKGEVB STARTUP TIME Vo Vo VBULK VBULK Figure 13. Input Voltage 85 Vac and 0.4 A Load Figure 14. Input Voltage 110 Vac and 0.4 A Load Vo Vo VBULK VBULK Figure 15. Input Voltage 230 Vac and 0.4 A Load Figure 16. Input Voltage 265 Vac and 0.4 A Load www.onsemi.com 6 NCP1060FLBKGEVB POWER OFF Vo Vo VBULK VBULK Figure 17. Input Voltage 85 Vac and 0.4 A Load Figure 18. Input Voltage 110 Vac and 0.4 A Load Vo Vo VBULK VBULK Figure 19. Input Voltage 230 Vac and 0.4 A Load Figure 20. Input Voltage 265 Vac and 0.4 A Load www.onsemi.com 7 NCP1060FLBKGEVB Table 3. BILL OF MATERIALS Designator Qty Description Value Tolerance C1 1 Capacitor 10 nF 10% Manufacturer Part Number Substitution Allowed Vishay BC Components BFC237261103 Yes Footprint Manufacturer Through hole C2 1 Ceramic Capacitor 1.0 nF 10% 805 Kemet C0805C102K5RACTU Yes C3, C4 2 Electrolytic Capacitor 10 mF / 400 V 20% Through hole Würth Elektronik 860011375006 Yes C5 1 Electrolytic Capacitor NU C6 1 Electrolytic Capacitor 470 mF / 16 V 20% Through hole Würth Elektronik 870235375008 Yes C7 1 Electrolytic Capacitor 470 mF / 16 V 20% Through hole Würth Elektronik 870235375008 Yes C8, C11 2 Ceramic Capacitor 100 nF 10% 805 Kemet C0805C104K5RAC Yes C9 1 Ceramic Capacitor NU C10 1 Electrolytic Capacitor 10 mF / 35 V 20% Through hole Würth Elektronik 870055673001 Yes C12 1 Ceramic Capacitor 2.2 nF 10% 805 Kemet C0805C222K5RACTU Yes C13 1 Ceramic Capacitor 12 nF 10% 805 Kemet C0805C123K5RACTU Yes C14 1 Electrolytic Capacitor 4.7 mF / 35 V 20% Through hole Würth Elektronik 860010572001 Yes CX1 1 Capacitor X2 68 nF 10% Through hole Würth Elektronik 890334025013CS Yes CX2 1 Capacitor X2 150 nF 10% Through hole Würth Elektronik 890334025022 Yes CY 1 Capacitor X1Y1 1.0 nF 20% Through hole Murata DE1E3KX102MA5BA01 Yes D1, D4, D5, D6 4 Diode MRA4007 SMA ON Semiconductor MRA4007T3G No D2 1 Diode MURA160 SMA ON Semiconductor MURA160T3G No D3 1 Diode MBRS1100 SMC ON Semiconductor MBRS1100T3G No D7 1 Diode MMSD4148 SOD123 ON Semiconductor MMSD4148T3G No IC1 1 Switcher NCP1060 PDIP−7 ON Semiconductor NCP1060AP060G No L1 1 Inductor 2.2 mH WE−TPC _2828 Würth Elektronik 744025002 No L2 1 Inductor 1.0 mH RFB0807 Würth Elektronik 768772102 No L3 1 Inductor NU RFB0807 L4 1 Common Mode Filter Choke 12 mH WE−TFC Würth Elektronik 744862120 No OK1 1 Optocoupler FOD817 SMD−4 Fairchild Semiconductor FOD817CS No R1 1 Resistor 15 W 1% 805 Rohm Semiconductor MCR10ERTF15R0 Yes R2 1 Resistor 270 kW 1% 0207/10 Vishay Dale CMF55270K00FKEB Yes R3 1 Resistor 20 W 5% 613 Vishay BC Components AC03000002009JAC00 Yes R4 1 Varistor 820572711 Through hole Würth Elektronik 820572711 No R5 1 Resistor 4.7 kW 1% 805 Rohm Semiconductor MCR10ERTF4701 Yes R6 1 Resistor 560 kW 1% 805 Rohm Semiconductor MCR10ERTF5603 Yes R7 1 Resistor 1.0 kW 1% 805 Rohm Semiconductor MCR10ERTF1001 Yes Through hole 805 www.onsemi.com 8 NCP1060FLBKGEVB Table 3. BILL OF MATERIALS Designator Qty Description Value Tolerance R8 1 Resistor 33 kW 1% Footprint 805 Manufacturer Part Number Substitution Allowed Rohm Semiconductor MCR10ERTF3302 Yes Manufacturer R9 1 Resistor NU 805 R10 1 Resistor 0.0 W 805 Vishay Dale CRCW08050000Z0EA Yes R11 1 Resistor 4.7 MW 5% Axial Lead Welwyn VRW37−4M7JI Yes R12 1 Resistor 9.1 kW 1% 805 Rohm Semiconductor MCR10ERTF9101 Yes R13 1 Resistor 200 kW 1% 805 Rohm Semiconductor MCR10ERTF2003 Yes R14 1 Resistor 10 W 1% 805 Rohm Semiconductor MCR10ERTF10R0 Yes TR1 1 Transformer 750370026 Through hole Würth Elektronik 750370026 No VR1 1 Voltage Regulator NCP431 TO−92 ON Semiconductor NCP431ACLPRAG No X1, X2 2 Wago Screw Clamp 237−102 unknown 70K9898 69110171000 2 Through hole Würth Elektronik 691101710002 No − 2 Wire Strap (insulated) − Wire strap Various Board Standoff 4 Hex Standoff M3 Nylon 8.0 mm 1% Yes Yes Harwin R30−1610800 Yes NOTE All components are lead free. REFERENCES [1] ON Semiconductor datasheet for NCP1060 monolithic switcher [2] ON Semiconductor design notes DN05012, DN05017, DN05018, DN05028, DN05029 [3] Würth Elektronik http://www.we−online.com/ Disclaimer ON Semiconductor is providing this Evaluation Board Manual “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. ON Semiconductor and the are registered trademarks of Semiconductor Components Industries, LLC (SCILLC) or its subsidiaries in the United States and/or other countries. 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