General Description NCP1231 implements standard current mode control a

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General Description NCP1231 implements standard current mode control a

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AND8155/D NCP1231 Watt, Universal Input Adapter Power Supply
General Description NCP1231 implements standard current mode control architecture. It's ideal candidate applications where parts count parameter, particularly cost adapter power supplies. NCP1231 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 NCP1231 controller. NCP1231 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, NCP1231 dedicated which used Brown-Out (BO) Overvoltage Protection (OVP) (Pin
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 with Load Symbol 18.6 19.38 4.74
Current-Mode Control Loss Startup Circuit Operation Over Universal Input Range Direct Connection Controller Standby Brown-Out Overvoltage Protection Programmable Soft Start
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 NCP1231 driving flyback power stage. output second stage capable output power. fully
MC33260 Critical Conduction Mode controller; result switching frequency function boost inductor timing capacitor. this application minimum operating frequency kHz.
33.33
(Vac)2
3.86
value used
Semiconductor Components Industries, LLC, 2004
June, 2004 Rev.
Publication Order Number: AND8155/D
AND8155/D
Where:
33.33 Freq
Vomin input) Where: switching frequency oscillator timing capacitor calculated following formula:
Kosc Cint Vpk2
output drives pulses external MOSFET, MOSFET, drives primary transformer second winding (VAuxiliary) which provides power NCP1231. When output power supply regulation, NCP1231 PFC_Vcc output (Pin will provide power MC33260 controller. startup resistors (R11 R12) power dissipation should calculated maximum expected output voltage PFC, Vdc. Each startup resistors will approximately half voltage:
Vstartupresistor Vdcbus 193.5
6400 1202
power each resistor
193.5 0.05
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 NCP1231 very startup current, (typical). result NCP1231 connected directly high voltage through high ohmage resistor(s). resistors should sized minimum anticipated voltage, NCP1231 Demo Board, Vdc. Before enabled NCP1231, minimum voltage
Vdcbus
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
charging current Istartup (NCP1231) plus current required charge capacitor. capacitor used this application capacitor used that under Standby power fault conditions, will drop below Vccmin (7.6 typical). trade-off made between startup time power dissipation startup resistors (refer application schematic) while operating standby power mode. start-up time seconds used this application.
icharge CVcc 12.6 29.6
Freq
112.5 0.566
Itotal 29.6 79.1 Rstartup 79.6 Itotal
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
Demo Board resistors were used series (refer Demo Board schematic). When power first applied Demo Board, capacitor charged through startup resistors. When above VCCon (12.6 typical), controller delivers
112.5 3.97
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AND8155/D
following calculations used verify that current will Discontinuous under operating conditions.
Toff freq Toff Iopk
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
transformer secondary current
Irms_sec Ipk_prim 3.97 6.77 12.02 Arms
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
transformer Demo Board manufactured Cooper Electronics Technologies (www.cooperET.com) part number CTX22-16134. designer should take precautions that under startup conditions that 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 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
Vinmax Vspike DSmax 6.77 19.7
Where Vripple
12.02 (15.38 9.23) 0.05
NCP1231 requires that controller supplied through auxiliary winding transformer. nominal supply voltage controller Vdc.
naux naux Vaux(1 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) 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).
Output Rectifying Diode rectifying diode selected based upon peak inverse voltage diodes average forward current. peak inverse voltage across secondary transformer
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AND8155/D
6.77 0.005
average current through diode
Iavg 4.74
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
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.
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. clamping voltage selected first step calculate snubber resistor.
Rclamp Rclamp Vclamp (Vclamp Ipk2 Freq
Figure Voltage Turn
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
(700 (19.7 6.77)) 3.972
Where: output voltage forward voltage drop across output diode transformer turns ratio 6.77 transformer leakage inductance 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 Auxiliary winding Flyback transformer (T5) used because it's proportional output voltage. implement Zener diode (refer Figure Overvoltage Protection Circuit) connected from rectified output auxiliary winding NCP1231. there fault condition voltage increases above Zener diode (D20) breakdown voltage plus NCP1231 Latch-Off threshold (4.2 typical), current will flow through diode pulling BO/OVP high, latching controller.
snubber capacitor calculated from following equation. Application Note AN1679/D details snubber equations were derived.
Vclamp Vripple Freq Rclamp
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AND8155/D
OVPthreshold Vz(D20) latch-off threshold 17.2
Zener diode selected controller will Latch-Off prior having reach maximum allowable voltage level,
Vaux
disadvantage this approach power supply operating with front end, input voltage drops normal input voltage range, able provide high enough output voltage that NCP1231 will detect condition. While operating Off-Line application, following equation used calculate resistive divide. using front end, replace with output voltage. This equation neglects affects voltage ripple:
BO/OVP NCP1231
Figure Overvoltage Protection Circuit
Where: where power supply stop operating detect Brown-Out level from data sheet (0.23 typical) most accurate method analyze this circuit develop SPICE model. This will allow quick determination optimum value Cfilter. Brown-Out Protection Circuits
NCP1231
Brown-Out Protection Brown-Out (BO) protection prevents power supply from being overstressed cases where input mains drop out, significantly goes below normal operating range. condition occurs, NCP1231 controller turns drive output (pin waits input voltage back normal operating level. protection implemented ways, refer Figures Figure BO/OVP connected through high resistor(s) bus. avoid having controller shut down inadvertently, because ripple which affected line load conditions, hysteresis been added comparator reference. When comparator toggles, internal reference voltage changes from (typical) (typical), this effect latched. When voltage capacitor below normal operating voltage, NCP1231 drive output disabled. soon input voltage recovers normal operating range, drive pulses enabled. lower threshold (VBlow) level which drive output disabled dependent capacitor (refer Figure size capacitor. large enough, much ripple appear BO/OVP pin, there chance controller prematurely stopping drive output pulses. increasing C25, amount hysteresis selected. lower ripple that appears larger between VBhigh (when drive pulses enabled) VBOlow.
BO/OVP
Figure Brown-Out Protection Circuit
Resistor used series limit power dissipation across each resistor. When voltage Vdc, each resistor will have across (neglecting voltage across R14).
Vdcbus
power dissipation second method detecting condition shown Figure This circuit will able detect condition independent line load conditions. addition, because sampling bus, will work even front used. this configuration divider network, sample input voltage, sampled voltage half-waved rectified sinewave, where voltage bridge
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AND8155/D
this circuit configuration form pass filter with attenuate half wave rectified line voltage from level. Where desired Soft Start time this application msec), Charging/Discharging current, volts. this application standard capacitor value used. value capacitor selected Soft Start affects fault timer, following equation used find fault timer period.
Tfault
NCP1231
BO/OVP
Vtimerpk Vtimervalley Csoftstart timericharge
Tfault msec 1.36
Figure
analyze this circuit, SPICE model created. results analysis that each Brown-Out level (VBlow) comparator threshold trips when input below Vac, VBhigh tripped when input voltage increases above Vac. power dissipation resistors calculated maximum input line voltage, assuming Universal input, you're using PFC, maximum voltage.
timer charging current during fault condition 1.36 typical. Frequency Jittering period created pair comparators, refer Figure (4.0 upper threshold lower threshold) which charge discharge Soft Start capacitor times. Frequency Jittering time period calculated
tfreqjitter Vtimerpk Vtimervalley Csoftstart icharge
tfreqjitter 9.84 msec
Vref1 Icharge Idischarge Soft-start jittering fault
0.03
D1N5406
D1N5406
Vref
LM139
D1N5406
D1N5406
VOFF VAMPL FREQ
0.23
Figure Soft Start Comparators
Figure Spice Model
Soft Start, Timer, Frequency Dithering NCP1231 controller implements three functions, Soft Start, Frequency Jittering, fault over load timer. Soft Start activated during startup sequence, voltage Soft Start will ramp from zero volts (typical). Soft Start charging current (typical), when Soft Start capacitor voltage reaches Soft Start sequence complete. Soft Start capacitor calculated with following equation:
Slope Compensation Flyback converter operating continuous conduction mode with duty cycle greater than 50%, slope compensation required. 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. NCP1231 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.
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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.
addition pole, there zero associated with output capacitor(s) capacitors esr. each capacitors 0.022 (from data sheet).
2pCo 6.28 8800
0.022
Where: maximum output power output voltage output resistance
Ipk2
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. TL431 requires minimum current regulation:
Ropto(R22) Vfopto
Where: peak primary current transformer primary inductance switching frequency controller
Ipk2
Where: peak primary current current sense resistor control voltage feedback input voltage divided down factor three Combining equations open loop gain
this application changed reduce Standby 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 NCP1231 nominal Standby Power minimize standby power consumption, output voltage sense resistor divider network select consume less than
Vref
With current mode control, there pole associated with output capacitor(s) load resistors. this application there four 2200 capacitors parallel:
8800 pCoRo
Standby power consumption
57400 Rtotal
Standby power calculation:
P_R22 P_TL431 V_R22 Vopto)
secondary filter made does affect control loop because sensing output voltage before network.
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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 NCP1231 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.
Loop Gain Plot GAIN (db) -100 1000 10000 FREQUENCY (Hz) 100000 -100 DB(V(FB)) P(V(FB)) FREQUENCY Loop Phase Margin PHASE -100 -140 -180 1000 FREQUENCY 10000 100000
Figure Excel Spreadsheet Phase Margin
Figure Excel Spreadsheet Loop Gain
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 NCP1231 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 form standby power limits).
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1N5406
MUR460
+VDC
Figure NCP1231 Demo Board Schematic section
1N5406
0.22
0.47
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PFC_Vcc 1N5406 1N5406
MC33260 8.06k
SYNC
SPP07N60C3
0.68
+VDC
0.01
MUR16 PFC_Vcc
MBR20100CT
49.9
BAL99LT1
2200 2200 2200 2200
PFCBO/OVP
47mF
Figure DC-DC section
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BAL99LT1 SPP11N80S5
AND8155/D
NCP1231
SFH615AA-X007 TL431
AND8155/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 82.2 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 NCP1231 Demo Board Bill Materials
Description Cap. Ceramic, chip, Cap. Aluminum Elec., 2200 Cap. Aluminum Elec., 2200 Cap. Aluminum Elect, Cap, Ceramic, 0.01 1000 Cap. Aluminum Elec Cap. Aluminum Elec, Cap. Aluminum Elec Cap. Aluminum Elec, Cap, class, Cap, Cap. Ceramic, chip, 0.068 Cap. Ceramic, chip, Cap. Aluminum Elec., 2200 Cap. Aluminum Elec., 2200 Cap, Film, Cap. Ceramic, chip, Cap. Ceramic, chip, Cap. Ceramic, chip, Cap. Ceramic, chip, Cap, 0.47 Cap. Aluminum, Cap. Ceramic, chip, Cap. Ceramic, chip, Cap. Ceramic, chip, Cap, 0.22 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, Diode, Zener, Fuse, Connector 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 VJ0805Y823KXJ F1772-447-3000 ECOS2WP151CA VJ0805A100KXA VJ0805A102KXA VJ1206106KXAA F1772-422-3000 BAL19LT1 MUR160 1N5408 1N5408 1N5408 1N5408 MUR460 1N4006 1N4006 BAL19LT1 AZ23C18 AZ23C18 MBR20100CT AZ23C13 1025TD2A 171602 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 Vishay Roederstein Panasonic Vishay Vishay Vishay Vishay Roederstein Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor Semiconductor VISHAY VISHAY Semiconductor VISHAY Bussman Weidmuller Manufacturer
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Table NCP1230 Demo Board Bill Materials (continued)
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, Resistor, 27.4 Resistor, Resistor, Resistor, 8.06 Resistor, Resistor, Resistor, Resistor, Resistor, 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 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 CRCW8054700RJNTA CRCW12067422F CMF-55-7503FKRE CMF-55-7503FKRE CRCW080520R0JNTA CRCW08052742F CMF-55-1204FKRE CRCW25121R30F CRCW8058K06FKTA CFP-3104JT-00 CMF-55-1214FKRE CMF-55-1214FKRE CRCW8051K00FKTA CRCW8051K00FKTA CMF-55-1204FKRE CRCW8054R7JNTA CRCW805200RJNTA CFP-3104JT-00 CRCW805200RJNTA NCP1230D65 MC33260D TL431ACD SFH615AA-X007 CTX22-16134 3049K-ND 4672 590302B03600 590302B03600 590302B03600 Weidmuller Coil Craft Cooper Electronics Coilcraft Infineon Infineon Semiconductor VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY Semiconductor Semiconductor Semiconductor VISHAY Cooper Electronics Digi-key Keystone Aavid Aavid Aavid
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Notes
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Semiconductor registered trademarks Semiconductor Components Industries, (SCILLC). SCILLC reserves right make changes without further notice products herein. SCILLC makes warranty, representation guarantee regarding suitability products particular purpose, does SCILLC assume liability arising application product circuit, specifically disclaims liability, including without limitation special, consequential incidental damages. "Typical" parameters which provided SCILLC data sheets and/or specifications vary different applications actual performance vary over time. operating parameters, including "Typicals" must validated each customer application customer's technical experts. SCILLC does convey license under patent rights rights others. SCILLC products designed, intended, authorized components systems intended surgical implant into body, other applications intended support sustain life, other application which failure SCILLC product could create situation where personal injury death occur. Should Buyer purchase SCILLC products such unintended unauthorized application, Buyer shall indemnify hold SCILLC officers, employees, subsidiaries, affiliates, distributors harmless against claims, costs, damages, expenses, reasonable attorney fees arising directly indirectly, claim personal injury death associated with such unintended unauthorized use, even such claim alleges that SCILLC negligent regarding design manufacture part. SCILLC Equal Opportunity/Affirmative Action Employer. This literature subject applicable copyright laws resale manner.
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AND8155/D

General Description NCP1231 implements standard current mode control a

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