General Description NCP1230 implements standard current mode control a

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General Description NCP1230 implements standard current mode control a

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AND8154/D NCP1230 Watt, Universal Input Adapter Power Supply
General Description NCP1230 implements standard current mode control architecture. It's ideal candidate applications where parts count parameter, particularly cost adapter power supplies. NCP1230 combines standby power mode with event management scheme that will disable circuit during Standby, thus reducing load power consumption. Demo Board demonstrates wide range features found NCP1230 controller. NCP1230 PFC_Vcc output which provides power controller, other circuitry. PFC_Vcc enabled when output power supply regulation. event that there output fault, PFC_Vcc turned off, disabling controller, reducing stress semiconductors. addition excellent load power consumption, NCP1230 provides internal latching function that used over voltage protection pulling above
Features
self-contained includes bias supply that operates Auxiliary winding transformer.
Table Demo Board Specifications
Requirement Input Frequency Output Power efficiency Standby Power Short Circuit Load with Load Symbol 18.6 19.38 4.74
Current-Mode Control Lossless Startup Circuit Operation Over Universal Input Range Direct Connection Controller Standby Overvoltage Protection
MC33260 configured Boost Follower operating from universal input line. section designed provide approximately power.
3.86
Design Specification This Demo Board configured stage adapter power supply. first stage operates universal input, 85-265 Vac, 50-60 using MC33260 Critical Conduction Mode controller, Boost Follower mode. output voltage from Boost Follower (when Vac) input line increases output Boost Follower will ramp Vdc. second stage power supply features NCP1230 driving flyback power stage. output second stage capable output power. fully
Semiconductor Components Industries, LLC, 2004
MC33260 Critical Conduction Mode controller; result switching frequency function boost inductor timing capacitor. this application minimum operating frequency kHz.
33.33
(Vac)2
(85)2
3.86
value used
June, 2004 Rev.
Publication Order Number: AND8154/D
AND8154/D
Where:
33.33 Freq 112.5 0.566
Vomin input) oscillator timing capacitor calculated following formula:
Kosc Cint Vpk2
this application primary inductance used This takes into consideration transformer tolerances, minimize transformer size. Once primary inductance been calculated, next step determine peak primary current.
Ipk2
6400 1202
Where: Kosc 6400 (feedback resistor) value used Refer Semiconductor website Application Note AND8123/D additional MC33260 application information, Excel based development tool DDTMC33260/D. Startup Circuit Description High Voltage (pin NCP1230 controller connected directly high voltage bus. When input power turned internal current source turned (typically charging external capacitor pin. When capacitor above VCCoff, current source turned off, controller delivers output drive pulses external MOSFET, MOSFET, drives primary transformer transformer additional windings, auxiliary winding which provides power controller after power supply running, secondary winding which provided output power. Transformer transformer primary inductance selected current would discontinuous under operating conditions. result total switching period, Toff, must less than equal 1/frequency. following assumptions were used design process: Dmax Duty Cycle input with Efficiency 0.80 Freq
112.5 Iavg 112.5 0.566
Iavg
112.5 3.97
following calculations used verify that current will Discontinuous under operating conditions.
Toff freq Toff
Iopk
Iopk
Where:
transformer turns ratio 6.77
3.97 27.22
With primary inductance value Toff less than controller switching period. Excel spreadsheet designed using above equation help calculate correct primary inductance value; visit Semiconductor website copy spreadsheet. method calculating transformer turns ratio minimize voltage stress MOSFET (VDS) reflected output voltage.
VDSmax Vinmax Vspike
this application MOSFET selected. goal, safety purposes, limit VDSmax high line (including Vspike) limit power dissipation snubber clamp (refer section Applications Note titled "Snubber".) Vspike clamped
VDSmax Vinmax Vspike
6.77 19.7
Freq
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AND8154/D
NCP1230 requires that controller supplied through auxiliary winding transformer. nominal supply voltage controller Vdc.
naux Vaux(1-D max)
Adapter design four 2200 (8800 total) capacitors (C2, C14, C15) were required parallel handle ripple current. small filter been added output power supply help reduce output ripple. cut-off frequency filter
15.6
13.7(1-0.4) naux 0.128 200(0.4)
supply voltage controller higher than calculated value because transformer leakage inductance. leakage inductance spike auxiliary winding averaged rectifier capacitor Because this, Zener diode (D18 refer Demo Board Schematic Figure connected from ground. limit current into Zener diode resistor placed between (R28). Semiconductor recommends that capacitor least sure that supply voltage does drop below Vccmin (7.6 typical) during standby power mode unusual fault conditions. transformer primary current
Irms 3.97 1.45 Arms
Output Rectifying Diode rectifying diode selected based upon peak inverse voltage diodes average forward current. peak inverse voltage across secondary transformer
6.77
average current through diode
Iavg 4.74
transformer secondary current
Irms_sec Ipk_prim 3.97 6.77 12.02 Arms
MBR20100CT Schottky diode selected; rated VRRM with average forward current Power Switch MOSFET selected power switching element. Several factors were used selecting MOSFET; current, voltage stress (VDS), RDS(on). current through primary transformer same current MOSFET, which 1.45 Arms. MOSFET selected manufactured Infineon, part number SPP11N80C3. rated Arms, with RDS(on) 0.45 Snubber maximum voltage across MOSFET
Vf)n 0.7) 6.77
transformer Demo Board manufactured Cooper Electronics Technologies (www.cooperET.com) part number CTX22-16134. designer should take precautions that under startup conditions, transformer will saturate input line Vac) full load conditions. above calculation assumed that adapter running front enabled. Output Filter disadvantages Flyback converter operating Discontinuous mode there large ripple current output capacitor(s). result required multiple capacitors parallel handle ripple current.
I_cap_ripple Iorms2 I_cap_ripple 12.022 4.742 11.04 6.15 65000 frequency Iorms (T-Ton) Vripple
This calculation neglects voltage spike when MOSFET turns transformer leakage inductance. spike, leakage inductance, must clamped level below MOSFETs' maximum VDS. clamp voltage spike resistive, capacitive, diode clamp network used prevent drain voltage from rising above Vclamp. desired clamp voltage this provides safety margin first step calculate snubber resistor.
Rclamp Rclamp Vclamp (Vclamp Ipk2 Freq
Where Vripple
12.02 (15.38-9.23) 0.05
(700 (19.7 6.77)) 3.972
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Where: output voltage forward voltage drop across output diode transformer turns ratio 6.77 transformer turns ratio power dissipation clamp resistor
PRclamp Ipk2 Freq PRclamp 3.972 Vclamp Vclamp (19.7 6.77) 0.23 4.43
used. reduce power dissipation sense resistor, resistors were used parallel. Overvoltage Protection NCP1230 fast comparator which only monitors current sense during power switch time. voltage current sense rises above (typical), NCP1230 will immediately stop output drive pulses latch-off controller. NCP1230 will stay Latch-Off mode until dropped below This feature allows user implement several protection functions, example, Overvoltage Overtemperature Protection. Auxiliary winding Flyback transformer (T5) used overvoltage protection because voltage Auxiliary winding proportional output voltage. implement Overvoltage Protection (OVP), transistor used bias current sense during NCP1230 controller time (refer Figure base transistor driven NCP1230 drive output (pin Auxiliary winding voltage increases above Zener diode (D1) breakdown voltage, current will flow through biasing voltage current sense pin. Using typical component values, voltage Auxiliary winding reaches 16.5 (3.5 above nominal voltage) NCP1230 will latch-off through input (pin
OVPthreshold Vz(D1) VceQ3 CSlatchoff 16.5
snubber capacitor calculated from following equation. Application Note AN1679/D details snubber equations were derived.
Vclamp Vripple Freq Rclamp
0.005
After initial snubber calculated, snubber values were tuned circuit minimize ringing, minimize power dissipation. result final circuit values are; Rclamp uses three equivalent), resistors used parallel, 0.01 1000 Refer Figure scope waveform Drain source voltage full load high line.
Zener diode selected have controller Latch-Off prior having reach maximum allowable voltage level,
Vaux MMBT2907A/SOT
Figure
NCP1230
Current Sense Resistor Selection input current sense amplifier clamped (typical). current sense resistor should calculated 125% full rated load sure that under operating conditions power supply will able deliver full rated power.
1.25 112.5 112.5 140.63 0.80 140.63 4.43
Rsense
Figure Overvoltage Protection Circuit
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AND8154/D
Overtemperature Protection implement Overtemperature Protection (OTP) shutdown, Zener diode replaced (refer Figure placed parallel with Zener diode have protection. When overtemperature condition occurs, resistance will decrease, allowing current flow through transistor biasing Current Sense pin.
Vaux MMBT2907A/SOT NCP1230
Where: peak primary current transformer primary inductance switching frequency controller
Ipk2
Rsense
Where: peak primary current current sense resistor control voltage feedback input voltage divided down factor three Combining equations open loop gain
Figure Overtemperature Protection Circuit
Slope Compensation Flyback converter operating continuous conduction mode with duty cycle greater than requires slope compensation. this application power supply will always operating discontinuous mode, slope compensation required. resistor capacitor form pass filter suppressing leading edge current signal. Typically, leading edge current will have large spike transformer leakage inductance. spike filtered, prematurely turn MOSFET. NCP1230 does have leading edge blanking circuit, good design practice external filter. time constant filter must significantly higher than highest expected operating frequency, enough filter spike. Output Control Feedback theory states that control loop stable there must least phase margin when loop gain crosses cross zero following equations derive Flyback converter transfer function while operating discontinuous continuous mode.
With current mode control, there pole associated with output capacitor(s) load resistors. this application there four 2200 capacitors parallel:
8800 pCoRo
secondary filter made does affect control loop because sensing output voltage before network. addition pole, there zero associated with output capacitor(s) capacitors esr. each capacitors 0.022 (from data sheet).
2pCo 6.28 8800
0.022
small 0.47 capacitor (C25) connected from feedback ground reduce switching noise feedback pin. Care must taken have large capacitor, frequency pole created feedback loop. Output Voltage Regulation output voltage regulation achieved using TL431 secondary side transformer. output voltage sensed divided down reference level TL431 (2.5 typical) resistive divider network consisting R10.
Where: maximum output power output voltage output resistance
Ipk2
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TL431 requires minimum current regulation:
Ropto(R22) Vfopto
GAIN Loop Gain Plot -100 1000 10000 FREQUENCY 100000
this application changed minimize stand power consumption. When power supply operating load, there sufficient current through optocoupler LED, resistor (R7) placed parallel. resistor selected. optocoupler gain
DVfb Ropto dBgain 20log20
current transfer ratio opto nominally 1.0, over time will degrade analysis circuit with recommended. internal pull-up resistor NCP1230 nominal Standby Power minimize standby power consumption, output voltage sense resistor divider network select consume less than
Vref
Figure Excel Spreadsheet Loop Gain
Loop Phase Margin PHASE -100 -140 -180 1000 FREQUENCY 10000 100000
Standby power consumption
57400 Rtotal
Standby power calculation:
P_R22 P_TL431 V_R22 Vopto)
Figure Excel Spreadsheet Phase Margin
Control Loop methods were used verify that Demo Board loop stable, results shown below. first method Excel Spreadsheet (using previously derived equations) which down loaded from Semiconductor website (www://onsemi.com). results from Excel Spreadsheet shown below. full load (200 minimum voltage being supplied from PFC) loop gain crosses zero approximately with approximately 100° phase margin. second method model NCP1230 Demo Board PSPICE. result seen Figure Because parasitic elements added PSPICE model, more accurate high frequencies. results from PSPICE model frequencies) shows similar results, loop gain crosses zero approximately with about phase margin.
-100 DB(V(FB))
P(V(FB))
FREQUENCY
Figure SPICE Phase/Gain
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NCP1230
CTRL
XFMR1
0.16
MUR810
out1
NCP1230 averaged
0.22 0.20 RATIO=0.1477 0.022 0.022 0.022 0.022 Rload
ACMAG=1 Vstim
2200 2200mF 2200mF 2200
49.9 MOC8101 TL431
0.47
Figure Frequency Response SPICE Model
Demo Board Test Procedure Connect power source connector. Connect load connector. Place Digital Voltage Meter (DVM) directly across output terminals. power source Vac, turn source. NCP1230 controller will turn-on supply
load (refer Table load regulation). Vary load from 4.73 monitor output voltage. Adjust power source from 85-265 monitor output voltage. power source Vac, disconnect load monitor standby power (refer Table standby power limits).
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1N5406 1N5406
MUR460
+VDC
Figure NCP1230 Demo Board Schematic section
0.22
0.47
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PFC_Vcc 1N5406 1N5406
MC33260 8.06k
SYNC
SPP07N60C3
0.68
+VDC
0.01
100k
100k 100k
1N4006 1N4006
MUR160 BAL19LT1
MBR20100CT
49.9k 2200 2200 2200 2200 7.4k 47mF
Figure DC-DC section
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PFC_Vcc
MMBT2907A/SOT
BAL19LT1 SPP11N80C3
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NCP1230
2.2nF
100pF
4.7k
SFH615AA-X007 TL431
AND8154/D
Table Voltage Regulation Efficiency
(Vac) 54.50 54.40 53.21 53.1 (Vdc) 19.02 19.03 19.06 19.06 (Adc) 2.36 2.36 2.36 2.36 82.57 82.72 84.54 84.71
112.00 110.84 109.42 109.01
18.82 18.88 18.88 18.89
4.77 4.77 4.77 4.77
80.36 81.2 82.25 82.56
Table Power Factor Distortion
(Vac) 112.00 110.84 109.42 109.01 0.996 0.996 0.972 0.965 19.01 23.0 (Vdc) 18.82 18.88 18.88 18.89
Table Standby Power
Test Standby Power Short Circuit with Load Condition (Vac input) Requirement (mW) Measured (mW)
Table Vendor Contact List
Semiconductor Infineon Coilcraft Vishay Coiltronics Bussman (Cooper Ind.) Panasonic Weidmuller Keystone Smith Aavid Thermalloy www.onsemi.com 1-800-282-9855 www.component.tdk.com 1-847-803-6100 www.infineon.com www.coilcraft.com www.vishay.com www.cooperet.com 1-888-414-2645 www.cooperet.com 1-888-414-2645 www.eddieray.com/panasonic.com www.weidmuller.com www.keyelco.com 1-800-221-5510 www.hhsmith.com 1-888-847-6484 www.aavid.com
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Table NCP1230 Demo Board Bill Materials
Description Cap. Ceramic, chip, Cap. Aluminum Elec., 2200 Cap. Aluminum Elec., 2200 Cap. Aluminum Elec., Cap, Ceramic, 0.01 1000 Cap. Aluminum Elec., Cap. Aluminum Elec., Cap. Aluminum Elec., Cap. Aluminum Elec., Cap, class, Cap, 0.01 Cap. Ceramic, chip, 0.068 Cap. Ceramic, chip, Cap. Aluminum Elec., 2200 Cap. Aluminum Elec., 2200 Cap, Film, 0.47 Cap. Ceramic, chip, Cap. Ceramic, chip, Cap. Ceramic, chip, Cap, 0.47 Cap. Aluminum, Cap. Ceramic, chip, Cap. Ceramic, chip, Cap, 0.22 Diode, Zener, Diode, Signal, Diode, Ultra Fast, Diode, Rectifier, Diode, Rectifier, Diode, Rectifier, Diode, Rectifier, Diode, Ultra-Fast, Diode, Rectifier, Diode, Rectifier, Diode, Signal, Diode, Zener, Diode, Zener, Diode, Schottky, Fuse, Part Number VJ0805Y104KXA EEUFC1E222 EKB00JG422F00 EEUFC1E222 EKB00JG422F00 EKB00BA310F00 225261148036 EEUFC1E470 EKB00AA247F00 EEUFC1E470 EKB00AA247F00 F1710-222-1000 F1772-410-3000 VJ0805Y683MXA VJ0805471KXA EEUFC1E222 EKB00JG422F00 EEUFC1E222 EKB00JG422F00 F1772-410-3000 VJ0805Y681KXA VJ0805Y104KXA VJ0805Y103KXA F1772-447-3000 ECOS2WP151CA VJ0805A100KXA VJ0805Y102KXA F1772-422-3000 AZ23C13 BAL19LT1 MUR160 1N5408 1N5408 1N5408 1N5408 MUR460 1N4006 1N4006 BAL19LT1 AZ23C18 AZ23C18 MBR20100CT 1025TD2A Vishay Panasonic VISHAY Panasonic VISHAY Vishay Vishay Panasonic Vishay Panasonic Vishay Vishay Roederstein Vishay Roederstein Vishay Vishay Panasonic VISHAY Panasonic VISHAY Vishay Roederstein Vishay Vishay Vishay Vishay Roederstein Panasonic Vishay Vishay Vishay Roederstein VISHAY Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor VISHAY VISHAY Semiconductor Bussman Manufacturer
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Table NCP1230 Demo Board Bill Materials (continued)
Connector Connector Inductor, Inductor, Inductor, Inductor, Common Mode Inductor, MOSFET, MOSFET, Bipolar transistor, Resistor, Resistor, Resistor, Resistor, 49.9 Resistor, Resistor, Resistor, Resistor, 7.42 Resistor, Resistor, Resistor, 8.06 Resistor, Resistor, Resistor, Resistor, Resistor, Jumper, Resistor, Resistor, Resistor, Resistor, Resistor, Flyback Controller Controller Programmable Reference Opto Coupler Flyback Transformer Shoulder Washer Insulator Heatsink, TO-220 Heatsink, TO-220 Heatsink, TO-220 CRCW805200RJNTA CRCW80510K0JNTA CRCW8054R7JNTA CRCW805200RJNTA CFP-3104JT-00 NCP1230D65 MC33260D TL431ACD SFH615AA-X007 CTX22-16134 3049K-ND 4672 590302B03600 590302B03600 590302B03600 VISHAY VISHAY VISHAY VISHAY VISHAY Semiconductor Semiconductor Semiconductor Infineon Cooper Electronics Digi-key Keystone Aavid Aavid Aavid 171602 171602 DO33316P-222 TSL1315-101K2R5 TSL1315-101K2R5 CTX22-16708 E3506-A SPP11N80C3 SPP07N60C3 MMBT2907A WSL-2512.4 CFP-3104JT-00 WSL-2512.4 CRCW12064992F CRCW25121R30F CRCW25121R30F CRCW0805472JNTA CRCW12067422F CRCW805020RJNTA CRCW25121R30F CRCW8058K06FKTA CFP-3104JT-00 CMF-55-1004FKRE CMF-55-1004FKRE CRCW8051K00FKTA CRCW8051K00FKTA Weidmuller Weidmuller Coilcraft Cooper Electronics Coilcraft Infineon Infineon Semiconductor VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY
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Notes
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General Description NCP1230 implements standard current mode control a

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