And 8154
And 8154
And 8154
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APPLICATION NOTE
General Description
The NCP1230 implements a standard current mode
control architecture. Its 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 Demo 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.
CurrentMode Control
Lossless Startup Circuit
Operation Over the Universal Input Range
Direct Connection to PFC Controller
Low Standby
Overvoltage Protection
Min
Max
Input
Vac
85
265
Frequency
Hz
47
63
Vo
Vdc
18.6
19.38
Io
Adc
4.74
Output Power
90
efficiency
80
Standby Power
Vin 230 Vac
mW
150
mW
mW
100
0.8
2 2 Pin max
Vac
Ipk
Ipk
2 2 116
3.86 A
85
Design Specification
This Demo Board is configured as a two stage adapter
power supply. The first stage operates off of the universal
input, 85265 Vac, 5060 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
Semiconductor Components Industries, LLC, 2004
Symbol
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.
Features
Requirement
Vo
2
2 Tp
Lp
Vo Vac Ipk
2 33.33
Lp
Vac (Vac)2
200
2
85 (85)2
200 85 3.86
414 H
AND8154/D
Where:
112.5 432 H
Lp 22 0.566
0.4 265
1
Tp
1 33.33 sec
30
Freq min
Pin 1 Ipk2 Lp f
2
Ipk
2
CT 4 200 6400 400 116 15 809 pF
22 1202
Where:
Kosc = 6400
Ro = 2.0 M (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
2220 112.5
3.97 Apk
65
Toff
Tp
Lp Ipk
Vin
Ls Iopk
Vo Vf
Where:
Ls
Lp
n2
Transformer
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
Vdc bus = 200 Vdc input with Vin 85 Vac
Efficiency = 0.80
Freq = 65 kHz
Vo = 19 V
Vf = 0.7
Po = 90 W
90
Pin Po
0.8 112.5 W
n
PinLp f2
2 Pin
Iavg
2Dmax
Freq
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2
AND8154/D
In the 90 W Adapter design four 2200 F (8800 F 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 cutoff
frequency for the filter is:
Vaux(1D max)
Vin D max
13.7(10.4)
naux
0.128
200(0.4)
fp
L1 = 2.2 H
C8 = 47 F
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
Don
3.97 0.4 1.45 Arms
3
3
Iavg Po 90 4.74 A
19
Vo
1D
3
3.97 6.77 0.6 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.
Snubber
The maximum voltage across the MOSFET is:
Output Filter
One of the disadvantages of a Flyback converter operating
in the Discontinuous mode is there is a large ripple current
in the output capacitor(s). As a result you may be required
to use multiple capacitors in parallel to handle the ripple
current.
1
0.4 1
0.4 6.15 sec
65000
frequency
Co
Iorms (TTon)
Vripple
Rclamp
1
1
15.6 kHz
2 2.2 47
2 LC
12.02 (15.389.23)
1, 478 F
0.05
Rclamp
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3
2 Vclamp (Vclamp Vo n)
le Ipk2 Freq
AND8154/D
Rs 1 V 1 0.23
4.43
Ipk
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 H
The power dissipation in the clamp resistor is:
PRclamp 0.5 Ipk2 le Freq
PRclamp 0.5 3.972 7 65
VclampVclamp
(Vo n)
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 latchoff the controller. The NCP1230 will stay in the
LatchOff 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.
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 2). 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 latchoff through the CS input
(pin 3).
700 (700
19.7 6.77)
4.4 W
Vclamp
Vripple Freq Rclamp
700
0.005 F
20 65 110
MMBT2907A/SOT
Figure 1.
1
2
3
4
10 k
GTS HV
FB
CS VCC
GND DRV
8
6
5
1k
Rsense
100 pF
Po 90 1.25 112.5 W
Pin Po 112.5 140.63 W
0.80
eff
Ipk
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4
AND8154/D
Overtemperature Protection
To implement Overtemperature Protection (OTP)
shutdown, the Zener diode can be replaced by an NTC (refer
to Figure 3), 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.
Where:
I is the peak primary current
Lp is the transformer primary inductance
F is the switching frequency of the controller
Vo2 1 Ipk2 Lp f
2
Ro
Vo
i
Vaux
Ro 2f Lp n d
i Ip Rs Vc
3
NTC
MMBT2907A/SOT
Q3
R26
10 k
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:
NCP1230
1
2
3
4
GTS HV
FB
CS VCC
GND DRV
8
6
5
1k
Rsense
C24
100 pF
Vo
i
Ro 2Lp f n d
i Ipk Rs Vc
3
Vc 3 Rs Ipk
Slope Compensation
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.
Vo
Vc
1
1
9.3 Hz
8800 3.9
CoRo
Output Control
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.
1
1
2Co esr
6.28 8800
0.022
4
3.3 kHz
2
Po Vo
Ro
Where:
Po is the maximum output power
Vo is the output voltage
Ro is the output resistance
P 1 Ipk2 Lp f
2
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5
AND8154/D
Loop Gain Plot
60
Vo Vfopto
19 1 18 k
1 mA
1 mA
40
20
GAIN IN dB
0
20
40
60
80
100
10
100
dBgain 20log20 26 dB
Standby Power
To minimize the standby power consumption, the output
voltage sense resistor divider network was select to consume
less than 10 mW.
60
PHASE
100000
1000
10000
FREQUENCY IN Hz
R10
7.4
Vref Vo
19
2.5 V
7.4 50
R10 R4
20
20
60
100
140
2
2
P Vo 19 6.3 mW
57400
Rtotal
180
10
100
P_R22 I2 * R22 12 ma 2 k 2 mW
1000
FREQUENCY
10000
100000
180
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 6.
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.
100
100
10 Hz
DB(V(FB))
100 Hz
1.0 kHz
10 kHz
P(V(FB))
FREQUENCY
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6
100 kHz
AND8154/D
NCP1230 AV U7
Vin
200 Vdc
OUT
FB
GND
CTRL
IN
NCP1230
averaged
XFMR1
U6
R7
0.16
D4
MUR810
out1
L1
2.2 H
FS = 65 k
L = 0.22 mH
RI = 0.20
LoL
1k
RATIO=0.1477
R3
0.022
CoL
1k
ACMAG=1
R5
0.022
R8
0.022
R6
0.022
C4
C1
C5
C6
2200 F 2200F 2200F 2200 F
Vstim
FB
Rload
3.9
C7
47 F
R11
1k
R2
49.9 k
U10
R1
4.7 k
C2
470 nF
MOC8101
C3
0.47 nF
U9
TL431
R4
7.4 k
load (refer to Table 1 for load regulation). Vary the load from
0 to 4.73 Adc and monitor the output voltage. Adjust the ac
power source from 85265 Vac and monitor the output
voltage. Set the ac power source to 230 Vac, and disconnect
the dc load and monitor the standby power (refer to Table 4
for the standby power limits).
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7
D12
400 H
MUR460
+VDC
F1
1
D8
D9
1N5406 1N5406
L2
2
100 H
J4
1
2
C11
0.1
F
C27
0.22
F
L3
1
1
2
L5
C23
150 F
C17
0.1 F
R19
1M
3
4
4.5 mH
C22
0.47
F
R20
1M
PFC_Vcc
100 H
D11
D10
1N5406 1N5406
U1
MC33260
R17
8.06k
R16
1.3
R5
1.3
OSC
VC
CS
FB
SYNC VCC
GND DRV
R6
1.3
R27
SPP07N60C3
Q2
4.7
C18
680 pF
D17
18 V
C19
0.1 F
C12
0.68 F
C13
470 pF
GND
AND8154/D
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L4
+VDC
R24
0
R2
C6
0.01 F
R29
100k
R18
100k 100k
T5
D4 220 H
3
MUR160
R25
200
D2
R28
L1
2.2 H
R4
49.9k
D19
R26
10k
CS VCC
GND DRV
D16
BAL19LT1
R13
20
C10
2.2nF
Q1
SPP11N80C3
NCP1230
R21
1k
R1 R3
C24
C25
1.0 nF
100pF
C7
47 F
C1
0.1 F
D18
18 V
0.4 0.4
U13
R7
4.7k
C20
C3
2200
F
J2
R10
7.4k
C8
47F
1
2
AND8154/D
MMBT2907A/SOT
Q3
1
GTS HV
2
FB
C14
2200
F
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PFC_Vcc
C15
2200
F
1k
D13
1N4006
C2
2200
F
R22
D15
1N4006
BAL19LT1
C5
100 F
200
D1
13 V
MBR20100CT
SFH615AAX007
100 nF
U12
TL431
AND8154/D
Table 2. 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
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
Condition
(Vac input)
Requirement Pin
(mW)
Pin Measured
(mW)
Standby Power
230
150
120
230
100
100
230
800
600
www.onsemi.com 18002829855
TDK
www.component.tdk.com 18478036100
Infineon
www.infineon.com
Coilcraft
www.coilcraft.com
Vishay
www.vishay.com
Coiltronics
www.cooperet.com 18884142645
www.cooperet.com 18884142645
Panasonic
www.eddieray.com/panasonic.com
Weidmuller
www.weidmuller.com
Keystone
www.keyelco.com 18002215510
HH Smith
www.hhsmith.com 18888476484
Aavid Thermalloy
www.aavid.com
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10
AND8154/D
Table 6. NCP1230 Demo Board Bill of Materials
Ref Des
Description
Part Number
Manufacturer
C1
VJ0805Y104KXA
Vishay
C2
EEUFC1E222
EKB00JG422F00
Panasonic
VISHAY
C3
EEUFC1E222
EKB00JG422F00
Panasonic
VISHAY
C5
EKB00BA310F00
Vishay
C6
225261148036
Vishay
C7
EEUFC1E470
EKB00AA247F00
Panasonic
Vishay
C8
EEUFC1E470
EKB00AA247F00
Panasonic
Vishay
C10
F17102221000
Vishay Roederstein
C11
F17724103000
Vishay Roederstein
C12
VJ0805Y683MXA
Vishay
C13
VJ0805471KXA
Vishay
C14
EEUFC1E222
EKB00JG422F00
Panasonic
VISHAY
C15
EEUFC1E222
EKB00JG422F00
Panasonic
VISHAY
C17
F17724103000
Vishay Roederstein
C18
VJ0805Y681KXA
Vishay
C19
VJ0805Y104KXA
Vishay
C20
VJ0805Y103KXA
Vishay
C22
F17724473000
Vishay Roederstein
C23
ECOS2WP151CA
Panasonic
C24
VJ0805A100KXA
Vishay
C25
VJ0805Y102KXA
Vishay
C27
F17724223000
Vishay Roederstein
D1
AZ23C13
VISHAY
D2
BAL19LT1
ON Semiconductor
D4
MUR160
ON Semiconductor
D8
1N5408
ON Semiconductor
D9
1N5408
ON Semiconductor
D10
1N5408
ON Semiconductor
D11
1N5408
ON Semiconductor
D12
MUR460
ON Semiconductor
D13
1N4006
ON Semiconductor
D15
1N4006
ON Semiconductor
D16
BAL19LT1
ON Semiconductor
D17
AZ23C18
VISHAY
D18
AZ23C18
VISHAY
D19
MBR20100CT
ON Semiconductor
F1
1025TD2A
Bussman
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11
AND8154/D
Table 6. NCP1230 Demo Board Bill of Materials (continued)
J2
Connector
171602
Weidmuller
J4
Connector
171602
Weidmuller
L1
DO33316P222
Coilcraft
L2
TSL1315101K2R5
TDK
L3
TSL1315101K2R5
TDK
L4
CTX2216708
Cooper Electronics
L5
E3506A
Coilcraft
Q1
SPP11N80C3
Infineon
Q2
SPP07N60C3
Infineon
Q3
Bipolar transistor, 50 V
MMBT2907A
ON Semiconductor
R1
WSL2512.4 1%
VISHAY
R2
CFP3104JT00
VISHAY
R3
WSL2512.4 1%
VISHAY
R4
CRCW12064992F
VISHAY
R5
CRCW25121R30F
VISHAY
R6
CRCW25121R30F
VISHAY
R7
CRCW0805472JNTA
VISHAY
R10
CRCW12067422F
VISHAY
R13
Resistor, SM, 20 , 5%
CRCW805020RJNTA
VISHAY
R16
CRCW25121R30F
VISHAY
R17
CRCW8058K06FKTA
VISHAY
R18
CFP3104JT00
VISHAY
R19
CMF551004FKRE
VISHAY
R20
CMF551004FKRE
VISHAY
R21
CRCW8051K00FKTA
VISHAY
R22
CRCW8051K00FKTA
VISHAY
R24
Jumper, 22 AWG
R25
CRCW805200RJNTA
VISHAY
R26
CRCW80510K0JNTA
VISHAY
R27
CRCW8054R7JNTA
VISHAY
R28
CRCW805200RJNTA
VISHAY
R29
CFP3104JT00
VISHAY
U1
Flyback Controller
NCP1230D65
ON Semiconductor
U2
PFC Controller
MC33260D
ON Semiconductor
U12
TL431ACD
ON Semiconductor
U4
Opto Coupler
SFH615AAX007
Infineon
T1
Flyback Transformer
CTX2216134
Cooper Electronics
H1
Shoulder Washer
3049KND
Digikey
H2
Insulator
4672
Keystone
H3
Heatsink, TO220
590302B03600
Aavid
H4
Heatsink, TO220
590302B03600
Aavid
H5
Heatsink, TO220
590302B03600
Aavid
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AND8154/D
Notes
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13
AND8154/D
ON Semiconductor and
are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice
to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does SCILLC assume any liability
arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without limitation special, consequential or incidental damages.
Typical parameters which may be provided in SCILLC data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All
operating parameters, including Typicals must be validated for each customer application by customers technical experts. SCILLC does not convey any license under its patent rights
nor the rights of others. SCILLC products are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other applications
intended to support or sustain life, or for any other application in which the failure of the SCILLC product could create a situation where personal injury or death may occur. Should
Buyer purchase or use SCILLC products for any such unintended or unauthorized application, Buyer shall indemnify and hold SCILLC and its officers, employees, subsidiaries, affiliates,
and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death
associated with such unintended or unauthorized use, even if such claim alleges that SCILLC was negligent regarding the design or manufacture of the part. SCILLC is an Equal
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AND8154/D