NCP1230GEVB NCP1230 90 Watt, Universal Input Adapter Power Supply Evaluation Board User's Manual http://onsemi.com EVAL BOARD USER’S MANUAL General Description Design Specification The NCP1230 implements a standard current mode control architecture. It’s an ideal candidate for applications where a low parts count is a key parameter, particularly in low cost adapter power supplies. The NCP1230 combines a low standby power mode with an event management scheme that will disable a PFC circuit during Standby, thus reducing the no load power consumption. The 90 W Evaluation Board demonstrates the wide range of features found on the NCP1230 controller. The NCP1230 has a PFC_Vcc output pin which provides Vcc power for a PFC controller, or other circuitry. The PFC_Vcc pin is enabled when the output of the power supply is up and in regulation. In the event that there is an output fault, the PFC_Vcc pin is turned off, disabling the PFC controller, reducing the stress on the PFC semiconductors. In addition to excellent no load power consumption, the NCP1230 provides an internal latching function that can be used for over voltage protection by pulling the CS pin above 3.0 V. This Demo Board is configured as a two stage adapter power supply. The first stage operates off of the universal input, 85−265 Vac, 50−60 Hz, using the MC33260 Critical Conduction Mode controller, in the Boost Follower mode. The output voltage from the Boost Follower (when Vin is 85 Vac) is 200 V and as the input line increases to 230 Vac the output of the Boost Follower will ramp up to 400 Vdc. The second stage of the power supply features the NCP1230 driving a flyback power stage. The output of the second stage is 19 Vdc capable of 90 W of output power. It is fully self−contained and includes a bias supply that operates off of the Auxiliary winding of the transformer. Table 1. EVALUATION BOARD SPECIFICATIONS Current−Mode Control Lossless Startup Circuit Operation Over the Universal Input Range Direct Connection to PFC Controller Low Standby Overvoltage Protection Symbol Min Max Input Vac 85 265 Frequency Hz 47 63 Vo Vdc 18.6 19.38 Io Adc − 4.74 Output Power W − 90 efficiency h 80 − Standby Power Vin 230 Vac mW − 150 Pin Short Circuit Load Vin 230 Vac mW Pin with 0.5 W Load Vin 230 Vac mW Features • • • • • • Requirement 100 − 0.8 PFC The MC33260 is configured as a Boost Follower operating from the universal input line. The PFC section was designed to provide approximately 116 W of power. Ipk + August, 2012 − Rev. 1 Vac 2 · Ǹ2 · 116 Ipk + + 3.86 A 85 Figure 1. Evaluation Board Photo © Semiconductor Components Industries, LLC, 2012 2 · Ǹ2 · Pin max 1 Publication Order Number: EVBUM2131/D NCP1230GEVB Vdc bus = 200 Vdc input with Vin 85 Vac Efficiency = 0.80 Freq = 65 kHz Vo = 19 V Vf = 0.7 Po = 90 W The MC33260 is a Critical Conduction Mode controller; as a result the switching frequency is a function of the boost inductor and the timing capacitor. In this application the minimum operating frequency is 30 kHz. Lp + Lp + ǒ Vo Ǹ2 2 · Tp Ǔ * Vac · (Vac)2 Vo · Vac · Ipk ǒ 2 · 33.33 200 Ǹ2 Ǔ * 85 · (85)2 200 · 85 · 3.86 90 Pin + Po h + 0.8 + 112.5 W Iavg + Pin + 112.5 + 0.566 200 Vin + 414 mH The value used is 400 mH. Where: Tp + Lp + 1 + 1 + 33.33 m sec 30 Freq min Lp + Vomin = 200 Vdc (@ 85 Vac input) Vac = 85 Vac The oscillator timing capacitor is calculated by the following formula: CT + ǒ 2 · Pin ǒ 2 · Iavg D max Ǔ · Freq 2 · 112.5 + 432 mH 265 2 · 0.566 0.4 Ǔ In this application the primary inductance used is 220 mH. This takes into consideration the transformer tolerances, and to minimize the transformer size. Once the primary inductance has been calculated, the next step is to determine the peak primary current. 4 Vo2 Kosc Lp Pin * Cint Ro2 Vpk2 Pin + 1 · Ipk2 · Lp · f 2 4 · 2002 · 6400 · 400 · 116 CT + * 15 + 809 pF 22 · 1202 Ipk + Where: Kosc = 6400 Ro = 2.0 MW (feedback resistor) The CT value used is 820 pF Refer to the ON Semiconductor website for Application Note AND8123/D for additional MC33260 application information, and the Excel based development tool DDTMC33260/D. Ipk + Ǹ Pin · 2 Lp · f Ǹ 2 · 112.5 + 3.97 Apk 220 · 65 The following calculations are used to verify that the current will be Discontinuous under all operating conditions. Tp + Ton ) Toff u 1 freq Startup Circuit Description The High Voltage pin (pin 8) of the NCP1230 controller is connected directly to the high voltage DC bus. When the input power is turned on, an internal current source is turned on (typically 3.0 mA) charging up an external capacitor on the Vcc pin. When the Vcc capacitor is above VCCoff, the current source is turned off, and the controller delivers output drive pulses to an external MOSFET, Q1. The MOSFET, Q1, drives the primary of the transformer T1. The transformer has two additional windings, the auxiliary winding which provides power to the controller after the power supply is running, and the secondary winding which provided the 19 Vdc output power. Ton + Toff + Tp + Lp · Ipk Vin Ls · Iopk Vo ) Vf ǒLpVin· IpkǓ ) ǒLsVo·)IopkVf Ǔ Where: Ls + Lp n2 n is the transformer turns ratio 6.77 Transformer Tp + The transformer primary inductance was selected so the current would be discontinuous under all operating conditions. As a result the total switching period, Ton + Toff, must be less than or equal to 1/frequency. The following assumptions were used in the design process: Dmax = 0.4 Duty Cycle 220 · 3.97 4.8 · 27.22 ) + 10 ms 200 19 ) 0.7 With a primary inductance value of 220 mH, Ton + Toff is less than the controller switching period. An Excel spreadsheet was designed using the above equation to help calculate the correct primary inductance value; visit the ON Semiconductor website for a copy of the spreadsheet. http://onsemi.com 2 NCP1230GEVB One method for calculating the transformer turns ratio is to minimize the voltage stress of the MOSFET (VDS) due to the reflected output voltage. in the output capacitor(s). As a result you may be required to use multiple capacitors in parallel to handle the ripple current. VDSmax + Vinmax ) n · (Vo ) Vf) ) Vspike I_cap_ripple + ǸIorms2 ) Io2 In this application an 800 V MOSFET was selected. The goal, for safety purposes, is to limit VDSmax at high line (including the Vspike) to 700 V. To limit the power dissipation in the snubber clamp (refer to the section in the Applications Note titled “Snubber”.) Vspike is clamped at 167 V. n+ I_cap_ripple + Ǹ12.022 * 4.742 + 11.04 A Ton + Co + VDSmax * Vinmax * Vspike Vo ) Vf Co + 12.02 @ (15.38−9.23) + 1, 478 mF 0.05 In the 90 W Adapter design four 2200 mF (8800 mF total) capacitors (C2, C3, C14, and C15) were required in parallel to handle the ripple current. A small LC filter has been added to the output of the power supply to help reduce the output ripple. The cut−off frequency for the filter is: The NCP1230 requires that the controller Vcc be supplied through an auxiliary winding on the transformer. The nominal supply voltage for the controller is 13 Vdc. Vaux(1−D max) Vin · D max fp + 13.7(1−0.4) naux + + 0.128 200(0.4) 1 1 + + 15.6 kHz 2p ǸLC 2p Ǹ2.2 · 47 L1 = 2.2 mH C8 = 47 mF The supply voltage to the controller may be higher than the calculated value because of the transformer leakage inductance. The leakage inductance spike on the auxiliary winding is averaged by the rectifier D2 and capacitor C5. Because of this, an 18 V Zener diode (D18 refer to the Demo Board Schematic Figure 10) is connected from the Vcc pin to ground. To limit the current into the Zener diode a 200 W resistor is placed between C5 and the Vcc pin (R28). ON Semiconductor recommends that the Vcc capacitor be at least 47 mF to be sure that the Vcc supply voltage does not drop below Vccmin (7.6 V typical) during standby power mode and unusual fault conditions. The transformer primary rms current is: Irms + Ipk Iorms @ (T−Ton) Vripple Where Vripple = 50 mV. n + 700 * 400 * 167 + 6.77 19.7 naux + 1 0.4 + 1 0.4 + 6.15 m sec 65000 frequency Output Rectifying Diode The rectifying diode was selected based upon on the peak inverse voltage and the diodes average forward current. The peak inverse voltage across the secondary of the transformer is: PIV + Vin n ) Vo PIV + 400 ) 19 + 78 Vpk 6.77 The average current through the diode is: Iavg + Po + 90 + 4.74 A 19 Vo ǸDon + 3.97 Ǹ0.4 + 1.45 Arms 3 3 An MBR20100CT Schottky diode was selected; it is rated for a VRRM of 100 V, with an average forward current of 10 A. The transformer secondary rms current is: Ǹ1−D 3 + 3.97 · 6.77 Ǹ0.6 + 12.02 Arms 3 Irms_sec + Ipk_prim · n Power Switch A MOSFET was selected as the power switching element. Several factors were used in selecting the MOSFET; current, voltage stress (VDS), and RDS(on). The rms current through the primary of the transformer is the same as the current in the MOSFET, which is 1.45 Arms. The MOSFET selected is manufactured by Infineon, part number SPP11N80C3. It is rated for 800 VDS and 11 Arms, with an RDS(on) of 0.45 W. The transformer for the Demo Board was manufactured by Cooper Electronics Technologies (www.cooperET.com) part number CTX22−16134. The designer should take precautions that under startup conditions, the transformer will not saturate at the low input ac line (85 Vac) and full load conditions. The above calculation assumed that the adapter was running and the PFC front end was enabled. Output Filter One of the disadvantages of a Flyback converter operating in the Discontinuous mode is there is a large ripple current http://onsemi.com 3 NCP1230GEVB Snubber The maximum voltage across the MOSFET is: Vpk + Vin max ) (Vo ) Vf)n Vpk + 400 ) (19 ) 0.7) 6.77 + 534 V This calculation neglects the voltage spike when the MOSFET turns off due to the transformer leakage inductance. The spike, due to the leakage inductance, must be clamped to a level below the MOSFETs’ maximum VDS. To clamp the voltage spike a resistive, capacitive, diode clamp network was used to prevent the drain voltage from rising above Vin + (Vo + Vf) n + Vclamp. The desired clamp voltage is 700 V; this provides a safety margin of 100 V. The first step is to calculate the snubber resistor. 2 · Vclamp · ǒVclamp * Vo · nǓ Rclamp + Rclamp + Figure 2. Current Sense Resistor Selection le · Ipk2 · Freq 2 · 700 · ǒ700 * ǒ19.7 · 6.77ǓǓ 7 · 3.972 · 65 The input to the current sense amplifier is clamped to 1.0 V (typical). The current sense resistor should be calculated at 125% of the full rated load to be sure that under all operating conditions the power supply will be able to deliver the full rated power. + 110 kW Where: Vo = the output voltage Vf = the forward voltage drop across the output diode n is the transformer turns ratio 6.77 Ie is the transformer turns ratio of 7 mH The power dissipation in the clamp resistor is: ǒ ǒ PRclamp + 0.5 · Ipk2 · le · Freq · PRclamp + 0.5 · 3.972 · 7 · 65 · Po + 90 · 1.25 + 112.5 W Pin + Po + 112.5 + 140.63 W 0.80 eff Ipk + Ǔ Ǔ Vclamp Vclamp * ǒVo · nǓ 700 700 * ǒ19.7 · 6.77Ǔ Rs + The snubber capacitor can be calculated from the following equation. See Application Note AN1679/D for details of how the snubber equations were derived. C6 + 2 · 140.63 + 4.43 Apk 220 · 65 1V + 1 + 0.23 W 4.43 Ipk 0.2 W was used. To reduce the power dissipation in the sense resistor, two 0.4 W resistors were used in parallel. + 4.4 W C6 + Ǹ Overvoltage Protection The NCP1230 has a fast comparator which only monitors the current sense pin during the power switch off time. If the voltage on the current sense pin rises above 3.0 V (typical), the NCP1230 will immediately stop the output drive pulses and latch−off the controller. The NCP1230 will stay in the Latch−Off mode until Vcc has dropped below 4.0 V. This feature allows the user to implement several protection functions, for example, Overvoltage or Overtemperature Protection. The Auxiliary winding of the Flyback transformer (T5) can be used for overvoltage protection because the voltage on the Auxiliary winding is proportional to the output voltage. Vclamp Vripple · Freq · Rclamp 700 + 0.005 mF 20 · 65 · 110 After the initial snubber was calculated, the snubber values were tuned in the circuit to minimize ringing, and minimize the power dissipation. As a result the final circuit values are; Rclamp uses three 100 kW (33 kW equivalent), 2.0 W resistors used in parallel, and C6 is 0.01 mF, 1000 V. Refer to Figure 2 for a scope waveform of the Drain to source voltage at full load and high line. http://onsemi.com 4 NCP1230GEVB Slope Compensation To implement Overvoltage Protection (OVP), a PNP transistor is used to bias up the current sense pin during the NCP1230 controller off time (refer to Figure 3). The base of the PNP transistor is driven by the NCP1230 drive output (pin 5), if the Auxiliary winding voltage increases above the Zener diode (D1) breakdown voltage, 13 V, current will flow through Q3 biasing up the voltage on the current sense pin. Using typical component values, if the voltage on the Auxiliary winding reaches 16.5 V (3.5 V above the nominal voltage) the NCP1230 will latch−off through the CS input (pin 3). A Flyback converter operating in continuous conduction mode with a duty cycle greater than 50% requires slope compensation. In this application the power supply will always be operating in the discontinuous mode, so no slope compensation is required. The resistor R21 and capacitor C24 form a low pass filter suppressing the leading edge of the current signal. Typically, the leading edge of the current will have a large spike due to the transformer leakage inductance. If the spike is not filtered, it can prematurely turn off the MOSFET. The NCP1230 does have a leading edge blanking circuit, but it is a good design practice to add an external filter. The time constant of the filter must be significantly higher than the highest expected operating frequency, but low enough to filter the spike. OVPthreshold + Vz(D1) ) VceQ3 ) CSlatchoff + 13 V ) 0.5 V ) 3.0 V + 16.5 V A 13 V Zener diode was selected to have the controller Latch−Off prior to having Vcc reach its maximum allowable voltage level, 18 V. Output Control Vaux Feedback theory states that for the control loop to be stable there must be at least 45° of phase margin when the loop gain crosses cross zero dB. The following equations derive the Flyback converter transfer function while operating in the discontinuous continuous mode. 13 V MMBT2907A/SOT 10 k NCP1230 1 2 3 4 GTS HV FB CS VCC GND DRV 1k 8 2 Po + Vo Ro 6 5 Where: Po is the maximum output power Vo is the output voltage Ro is the output resistance Rsense 100 pF P + 1 · Ipk2 · Lp · f 2 Figure 3. Overvoltage Protection Circuit Where: I is the peak primary current Lp is the transformer primary inductance F is the switching frequency of the controller Overtemperature Protection To implement Overtemperature Protection (OTP) shutdown, the Zener diode can be replaced by an NTC (refer to Figure 4), or an NTC can be placed in parallel with the Zener diode to have OVP and OTP protection. When an overtemperature condition occurs, the resistance of the NTC will decrease, allowing current to flow through the PNP transistor biasing up the Current Sense pin. Vo2 + 1 · Ipk2 · Lp · f 2 Ro Vo + i i + Ip · Rs + Vc 3 Vaux Where: Ip is the peak primary current Rs is the current sense resistor Vc is the control voltage 3, the feedback input voltage is divided down by a factor of three Combining equations the open loop gain is: NTC MMBT2907A/SOT Q3 R26 10 k NCP1230 1 2 3 4 GTS HV FB CS VCC GND DRV 1k C24 100 pF ǸRo ·2f · Lp · n · d 8 6 5 Vo + i Rsense ǸRo ·2Lp · f · n · d i + Ipk @ Rs + Vc 3 Vc + 3 @ Rs @ Ipk Figure 4. Overtemperature Protection Circuit http://onsemi.com 5 NCP1230GEVB Vo + Vc ǸRo ·2Lp · f · n · d · Ipk · Rs · 3 The Standby power consumption is: 2 2 P + Vo + 19 + 6.3 mW 57400 Rtotal With current mode control, there is pole associated with the output capacitor(s) and the load resistors. In this application there are four 2200 mF capacitors in parallel: fp + Standby power calculation: P_R22 + I2 * R22 + 12 ma · 2 k + 2 mW 1 1 + + 9.3 Hz pCoRo p · 8800 · 3.9 P_TL431 + (Vo * V_R22 * Vopto) · 1 ma + 17 V · 1 ma + 17 mW The secondary filter made up of L1 and C8 does not affect the control loop because we are sensing the output voltage before the LC network. In addition to the pole, there is a zero associated with the output capacitor(s) and the capacitors esr. The esr of each capacitors is 0.022 W (from the data sheet). fz + 1 1 + 2pCo · esr 6.28 · 8800 · 0.022 4 Control Loop Two methods were used to verify that the Demo Board loop was stable, the results are shown below. The first method was to use an Excel Spreadsheet (using the previously derived equations) which can be down loaded from the ON Semiconductor website (www.onsemi.com). The results from the Excel Spreadsheet are shown below. At full load and 200 Vdc (200 Vdc is the minimum voltage being supplied from the PFC) the loop gain crosses zero dB at approximately 1.2 kHz with approximately 100° of phase margin. The second method was to model the NCP1230 Demo Board in PSPICE. The result can be seen in Figure 7. Because parasitic elements can be added to the PSPICE model, it was more accurate at high frequencies. The results from the PSPICE model (at low frequencies) shows similar results, the loop gain crosses zero dB at approximately 1.2 kHz with about 90° of phase margin. + 3.3 kHz A small 0.47 nF capacitor (C25) is connected from the feedback pin to ground to reduce the switching noise on the feedback pin. Care must be taken not to have too large a capacitor, or a low frequency pole may be created in the feedback loop. Output Voltage Regulation The output voltage regulation is achieved by using a TL431 on the secondary side of the transformer. The output voltage is sensed and divided down to the reference level of the TL431 (2.5 V typical) by the resistive divider network consisting of R4 and R10. The TL431 requires a minimum of 1.0 mA of current for regulation: Ropto(R22) + Loop Gain Plot 60 Vo * Vfopto + 19 * 1 + 18 k 1 mA 1 mA 40 20 GAIN IN dB In this application R22 was changed to 1.0 kW to minimize the stand by power consumption. When the power supply is operating at no load, there may not be sufficient current through the optocoupler LED, so a resistor (R7) is placed in parallel. A 4.7 kW resistor was selected. The optocoupler gain is: 0 −20 −40 −60 −80 DVfb + Rfb · CTR + 20 · 1.0 + 20 1 Ropto DVc −100 10 dBgain + 20log20 + 26 dB 1000 10000 FREQUENCY IN Hz 100000 Figure 5. Excel Spreadsheet Loop Gain CTR is the current transfer ratio of the opto and is nominally 1.0, but over time the CTR will degrade so analysis of the circuit with the CTR = 0.5 is recommended. Rfb is the internal pull−up resistor of the NCP1230 and it is a nominal 20 kW. Standby Power To minimize the standby power consumption, the output voltage sense resistor divider network was select to consume less than 10 mW. Vref + Vo 100 Ǔ + 2.5 V ǒR10R10 Ǔ + 19 ǒ7.47.4 ) 50 ) R4 http://onsemi.com 6 NCP1230GEVB Loop Phase Margin 180 180 140 100 100 PHASE 60 20 −20 0 −60 −100 −140 −100 10 Hz −180 10 100 1000 FREQUENCY 10000 100000 100 Hz DB(V(FB)) NCP1230 AV U7 + − Vin 200 Vdc OUT FB GND CTRL IN XFMR1 U6 R7 0.16 D4 MUR810 out1 L1 2.2 mH FS = 65 k L = 0.22 mH RI = 0.20 LoL 1k RATIO=0.1477 R3 0.022 R5 0.022 R8 0.022 R6 0.022 C4 C1 C5 C6 2200 mF 2200mF 2200mF 2200 mF Vstim FB R11 1k U10 R2 49.9 k R1 4.7 k C2 470 nF MOC8101 C3 0.47 nF 100 kHz Figure 7. SPICE Phase/Gain CoL 1k ACMAG=1 10 kHz FREQUENCY Figure 6. Excel Spreadsheet Phase Margin NCP1230 averaged 1.0 kHz P(V(FB)) U9 TL431 R4 7.4 k Figure 8. AC Frequency Response SPICE Model http://onsemi.com 7 Rload 3.9 C7 47 mF NCP1230GEVB Evaluation Board Test Procedure Figure 9. NCP1230GEVB Test Setup 8. Connect the Voltec Precision Power Analyzer as shown in Figure 9. 9. Turn on the ac source to 115 Vac at 60 Hz and set the electronic load to 90 W. (Only measure the THD at full load). 10. Verify that the current Harmonics (THD) are less than the maximum vales in Table 5. 11. Verify that the PF is greater than the minimum values in Table 5. 12. Set the ac source output to 230 Vac at 60 Hz. 13. Verify that the current Harmonics (THD) are less than the maximum vales in Table 5. 14. Verify that the PF is greater than the minimum values in Table 5. 15. Set the ac source to 115 Vac, set the load to 0 Adc, and measure the standby power, refer to Table 5 for the maximum acceptable input power. 16. Set the ac source to 230 Vac, and refer to Table 5 for the maximum input power. Table 2. TEST EQUIPMENT ac Source 85 − 265 Vac, 47 − 64 Hz Variable Electronic Load Digital Multimeter Voltec Precision Power Analyzer Test Setup 1. Connect the ac source to the input terminals J4. 2. Connect a variable electronic load to the output terminals J2, the PWB is marked +, for the positive output, and − for the return. 3. Set the variable electronic load to 45 W. 4. Turn on the ac source and set it to 115 Vac at 60 Hz. 5. Verify that the NCP1230 provides 19 Vdc to the load. 6. Vary the load and input voltage. Verify that the output voltage is within the minimum and maximum values as shown in Table 4. 7. To verify total harmonic distortion (THD) first, shut off the ac power supply. Table 3. EXPECTED VALUES FOR VARYING INPUT VOLTAGES AND LOADS Vin (Vac) Vo (Vdc) @ No Load Vo (Vdc) @ 45 W Vo (Vdc) @ 90 W THD (%) PF 90 W 90 19.1 19.0 18.8 6.5 0.995 115 19.1 19.0 18.8 7.8 0.995 230 18.7 19.1 18.8 20 0.97 Table 3 shows typical values, the initial set point (19.0 Vdc may vary). http://onsemi.com 8 NCP1230GEVB Table 4. REGULATION Vin (Vac) Pinmax (W) Vomin (Vdc) Vomax (Vdc) IO (Adc) Po (W) Eff (%) 90 115 18.7 19.1 4.85 90 80.0 115 114 18.7 19.1 4.85 90 80.0 230 112 18.7 19.1 4.85 90 81.0 Table 5. STAND-BY POWER Table 6. POWER FACTOR AND THD Vin (Vac) Pinmax (mW) Vin (Vac) PFmin (W) THDmax (%) PO (W) 115 150 90 0.990 8.0 90 230 200 115 0.990 9.0 90 230 0.96 21.0 90 http://onsemi.com 9 J4 1 2 1 2 C11 0.1 mF F1 L2 2 L3 2 100 mH 1 100 mH 1 C27 0.22 mF L5 4 3 4.5 mH 2 1 C22 0.47 mF http://onsemi.com 10 R16 1.3 D10 D11 1N5406 1N5406 D8 D9 1N5406 1N5406 R5 1.3 R6 1.3 8.06k R17 C17 0.1 mF C18 680 pF SYNC VCC GND DRV 4 5 6 7 8 D17 18 V FB CS 3 VC OSC 2 U1 MC33260 1 400 mH L4 C19 0.1 mF 4.7 R27 C12 0.68 mF C13 470 pF SPP07N60C3 Q2 MUR460 D12 C23 150 mF + R20 1M GND PFC_Vcc R19 1M +VDC NCP1230GEVB Figure 10. NCP1230 Demo Board Schematic − PFC section PFC_Vcc +VDC 11 Figure 11. DC−DC section http://onsemi.com 100pF C24 NCP1230 CS VCC GND DRV 5 6 C7 47 mF R2 R18 C1 0.1 mF R21 1k 2 + 3 4 4 5 7 6 U13 2 1 0.4 0.4 C10 2.2nF D19 C2 2200 mF U12 TL431 R7 4.7k 1k R22 MBR20100CT R1 R3 T5 100 nF C20 C15 2200 mF + SFH615AA−X007 D18 18 V Q1 SPP11N80C3 R13 20 D2 BAL19LT1 C5 100 mF D16 BAL19LT1 200 R28 R29 100k 100k D4 220 mH 3 MUR160 100k + C25 1.0 nF R26 10k 4 8 D13 1N4006 D15 1N4006 C6 0.01 mF + 3 MMBT2907A/SOT Q3 1 GTS HV 2 FB D1 13 V R25 200 R24 0 C14 2200 mF C3 2200 mF R10 7.4k 2.2 mH R4 49.9k L1 C8 47mF 1 2 J2 NCP1230GEVB + + + NCP1230GEVB Table 7. Voltage Regulation and Efficiency Vin (Vac) Pin (W) Vo (Vdc) Io (Adc) Po (W) Eff (%) 85 54.50 19.02 2.36 45 82.57 115 54.40 19.03 2.36 45 82.72 230 53.21 19.06 2.36 45 84.54 265 53.1 19.06 2.36 45 84.71 85 112.00 18.82 4.77 90 80.36 115 110.84 18.88 4.77 90 81.2 230 109.42 18.88 4.77 90 82.25 265 109.01 18.89 4.77 90 82.56 Table 8. Power Factor and Distortion Vin (Vac) Pin (W) PF THD (%) Vo (Vdc) Po (W) 85 112.00 0.996 6.5 18.82 90 115 110.84 0.996 7.7 18.88 90 230 109.42 0.972 19.01 18.88 90 265 109.01 0.965 23.0 18.89 90 Table 9. Standby Power Test Condition (Vac input) Requirement Pin (mW) Pin Measured (mW) Standby Power 230 150 120 Pin Short Circuit 230 100 100 Pin with 0.5 W Load 230 800 600 Table 10. Vendor Contact List ON Semiconductor www.onsemi.com 1−800−282−9855 TDK www.component.tdk.com 1−847−803−6100 Infineon www.infineon.com Coilcraft www.coilcraft.com Vishay www.vishay.com Coiltronics www.cooperet.com 1−888−414−2645 Bussman (Cooper Ind.) www.cooperet.com 1−888−414−2645 Panasonic www.eddieray.com/panasonic.com Weidmuller www.weidmuller.com Keystone www.keyelco.com 1−800−221−5510 HH Smith www.hhsmith.com 1−888−847−6484 Aavid Thermalloy www.aavid.com http://onsemi.com 12 NCP1230GEVB Table 11. NCP1230 EVALUATION BOARD BILL OF MATERIALS Designator QTY Description U9 1 U2 Manufacturer Manufacturer Part Number Substitution Allowed RoHS Compliant SOIC 8 ON Semiconductor NCP1230D65R2G No Yes SOIC 8 ON Semiconductor MC33260DG No Yes NA SOIC 8 ON Semiconductor TL431ACDG No Yes Value Tolerance Footprint Flyback Controller 18 V, 0.5 A NA 1 PFC controller 16 V, 0.6 A NA U12 1 Programable reference 2.5 V U4 1 Optocoupler 70 V, 50 Ma NA UL1577 Vishay SFH615A-3 Yes Yes C1, C19 2 Ceramic chip capacitor 0.1 uF, 50 V 10% 0603 Vishay VJ0603Y104KXAA Yes Yes C2, C3, C14, C15 4 Electorlytic Capacitor 2200 uF, 25 V 20% 16.0 mm x 25.0 mm Vishay EKB00JG422F00 Yes Yes C5 1 Electorlytic Capacitor 100 uF, 35 V 20% 6.3 mm x 11.0 mm Vishay EKB00BA310F00 Yes Yes C6 1 Cap, Ceramic 0.01uF, 1000V 10% Disc Vishay 562RZ5UBA102E103M Yes Yes C7, C8 2 Cap. Aluminum Elec 47 uF, 25 V 20% 5.0 mm x 11.0 mm Vishay EKB00AA247F00 Yes Yes C10 1 Capacitor, Y2 class 2.2 nF, 250 V 20% 5.3 mm x 10.3 mm Vishay F1710-222-1000 Yes Yes C11, C17 2 Capacitor, X2 class 0.1 uF, 300 V 10% 8.3 mm x 17.8 mm Vishay F1772-410-3000 Yes Yes C12 1 Ceramic chip capacitor 0.068 uF, 50 V 10% 0603 Vishay VJ0603Y683KXAA Yes Yes C13 1 Ceramic chip capacitor 470 pF, 50 V 10% 0603 Vishay VJ0603471KXAA Yes Yes C18 1 Ceramic chip capacitor 680 pF, 50V 10% 0603 Vishay VJ0603Y681KXAA Yes Yes C20 1 Cap. Ceramic, chip 0.047 uF, 16 V 10% 0805 Vishay VJ0805Y473KXJA Yes Yes Vishay F1772-447-3000 Yes Yes C22 1 Capaitor, X2 class 0.47 uF, 300 V 10% 13.0 mm x 31.3 mm C23 1 Cap. Aluminum 150uF, 450Vdc 20% 25mm x 40mm Panasonic ECOS2WP151CA Yes Yes C24 1 Ceramic chip capacitor 100 pF, 50 V 10% 0805 Vishay VJ0805100KXAA Yes Yes C25 1 Ceramic chip capacitor 1.0 nF, 50 V 10% 0805 Vishay VJ0805Y102KXAA Yes Yes C27 1 Capacitor, X2 class 0.22 uF, 300 V 10% 10.3 mm x 26.3 mm Vishay F1772-422-3000 Yes Yes D1 1 Zener Diode, SM 13 V, 0.3 W NA SOT-23 Vishay AZ23C13 Yes Yes BAS19LT1G No Yes D2, D16 2 Diode, signal 75V, 100ma NA SOT-23 ON Semiconductor D4 1 Diode, ultra fast 600 V, 1 A NA DO41 ON Semiconductor MUR160 No Yes D8, D9, D10, D11 4 Diode, rectifier 1000 V, 3 A NA DO201AD ON Semiconductor 1N5408G No Yes D12 1 Diode, ultra-fast 600 V, 4 A NA DO201AD ON Semiconductor MUR460 No Yes D13, D15 2 Diode, rectifier 800 V, 1 A NA DO41 ON Semiconductor 1N4006 No Yes D17, D18 2 Zener Diode, SM 18 V, 0.3 W NA SOT-23 Vishay AZ23C18 Yes Yes http://onsemi.com 13 NCP1230GEVB Table 11. NCP1230 EVALUATION BOARD BILL OF MATERIALS Manufacturer Manufacturer Part Number Substitution Allowed RoHS Compliant ON Semiconductor MBR20100CTG No Yes 10mm x 2.5mm Bussman 1025TD2 Yes Yes NA 5.08 mm Weidmuller 171602 Yes Yes 2.2 uH, 7.5 A 10% 13 mm x 9 mm Coilcraft DO3316P-222ML Yes Yes Inductor 100 uH, 2.5 A 10% 1315 TDK TSL1315-101K2R5 Yes Yes 1 PFC Indcutor 400 uH, 5 A 20% NA Cooper Electronics CTX22-16816 Yes Yes L5 1 Common Mode Inductor 508 uH, 3 A 30% NA Coilcraft E3506-AL Yes Yes Q1 1 MOSFET 0.8 W 800 V, 11 A NA TO220-31 Infineon SPP11N80C3 Yes Yes Q2 1 MOSFET 0.8 W 650 V, 7.3 A NA TO220-31 Infineon SPP07N60C3 Yes Yes Q3 1 Bipolar transistor 60 V, 0.6 A NA SOT-23 ON Semiconductor MMBT2907ALT1G No Yes R1, R3 2 Resistor 0.4 W, 1 W 1% 2512 Vishay WSL2512R4000FEA Yes Yes R2, R18, R29 3 Resistor 100k, 3W 5% 14.10 mm x 4.57 mm Vishay CPF3100k00JNE14 Yes Yes Value Tolerance Footprint Diode, schottky 100 V, 20 A NA TO220AB 1 Brick Fuse 250 Vac, 2 A NA J2, J4 2 PCB Connector 10 A, 300 V L1 1 Inductor L2, L3 2 L4 Designator QTY Description D19 1 F1 R4 1 Resistor 49.9 kW, 1/8 W 1% 0805 Vishay CRCW08054992FNEA Yes Yes R5, R6, R16 3 Resistor 1.3 W, 1 W 1% 2512 Vishay CRCW25121R30FNEA Yes Yes R7 1 Resistor 4.7 kW, 1/8 W 5% 0805 Vishay CRCW8054700RJNEA Yes Yes R10 1 Resistor 7.42 kW, 1/8 W 1% 0805 Vishay CRCW08057421FNEA Yes Yes R13 1 Resistor 20 W, 1/4 W 5% 1206 Vishay CRCW120620R0JNEA Yes Yes R17 1 Resistor 8.06 kW, 1/8 W 1% 0805 Vishay CRCW08058K06FKEA Yes Yes R19, R20 2 Resistor 1 MW, 1/8 W 1% 6.10 mm x 2.29 mm Vishay CMF551004FKEK Yes Yes R21, R22 2 Resistor 1 kW, 1/4 W 1% 1206 Vishay CRCW12061K00FKEA Yes Yes R24 1 Jumper, 22 AWG NA NA NA Any NA Yes Yes R25 1 Resistor 200 W, 1/4 W 5% 1206 Vishay CRCW1206200RJNEA Yes Yes R26 1 Resistor 10 kW, 1/4 W 5% 1206 Vishay CRCW120610K0JNEA Yes Yes R27 1 Resistor 4.7 W, 1/4 W 5% 1206 Vishay CRCW12064R7JNEA Yes Yes R28 1 Resistor 200 W, 1/4 W 5% 1206 Vishay CRCW1206200RJNEA Yes Yes T1 1 Flyback Transformer 220 uH, 3.3 Apk NA NA Cooper Electronics CTX22-16134 Yes Yes H1 1 Shoulder Washer NA NA #4 x 0.031” Keystone 3049 Yes Yes Keystone 4672 Yes Yes Aavid 590302B03600 Yes Yes H2 1 Insulator NA NA 0.86 ” x 0.52 ” H3, H4, H5 3 Heatsink NA NA TO-220 http://onsemi.com 14 NCP1230GEVB ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). 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